Mitsubishi Engine 4G6

11A-0-1

ENGINE 4G6 SERIES CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-4 NEW TIGHTENING METHOD BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA . . 11A-1-9 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-9 FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-10 2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2-1 3. ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1 3a. INTAKE MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-3a-1 4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4-1 4a. EXHAUST MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4a-1 5. FUEL AND EMISSION CONTROL PARTS . . . . . . . . . . . . . . . . . . . . . . 11A-5-1 5a. FUEL PARTS (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-5a-1 6. WATER PUMP AND INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1 6a. WATER PUMP AND WATER HOSE (GDI) . . . . . . . . . . . . . . . . . . . . . 11A-6a-1 7. EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1 8. ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-8-1 8a. ROCKER ARMS AND CAMSHAFTS (GDI) . . . . . . . . . . . . . . . . . . . 11A-8a-1 9. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-9-1 10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 11A-10-1 11. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-11-1 12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE . . . . . . . . . . . . . 11A-12-1

E Mitsubishi Motors Corporation

Aug. 1998

PWEE9616-A

Revised

11A-0-2 NOTES


Dec. 1996

PWEE9616

4G6 ENGINE - General Information

11A-0-3

GENERAL INFORMATION SOHC-4G63 Descriptions

Specifications

Type

In-line OHV, SOHC

Number of cylinders

4

Combustion chamber

Pentroof type

Total displacement dm3

1,997

Cylinder bore mm

85.0

Piston stroke mm

88.0

Compression ratio

10

Valve timing

Intake valve

Exhaust valve

Opens (BTDC)

18_

Closes (ABDC)

58_

Opens (BBDC)

58_

Closes (ATDC)

18_

Lubrication system

Pressure feed, full-flow filtration

Oil pump type

Involute gear type

SOHC-4G64 Descriptions

Specifications

Type

In-line OHV, SOHC

Number of cylinders

4

Combustion chamber

Pentroof type


2,351

Cylinder bore mm

86.5

Piston stroke mm

100.0

Compression ratio

10

Valve timing

Intake valve

Exhaust valve

Opens (BTDC)

16_

Closes (ABDC)

53_

Opens (BBDC)

50_

Closes (ATDC)

16_

Lubrication system


Oil pump type

Involute gear type


Aug. 1998

PWEE9616-A

Revised

11A-0-4

4G6 ENGINE - General Information

GDIt Descriptions

Specifications

Type

In-line OHV, SOHC

Number of cylinders

4

Combustion chamber

Pentroof + curved top piston type


2,351

Cylinder bore mm

86.5

Piston stroke mm

100.0

Compression ratio

11.5

Valve timing

Intake valve

Exhaust valve

Opens (BTDC)

16_

Closes (ABDC)

60_

Opens (BBDC)

56_

Closes (ATDC)

16_

Lubrication system


Oil pump type

Involute gear type

NOTE GDI is a trademark of Mitsubishi Motors Corporation.


Aug. 1998

PWEE9616-A

Added

11A-1-1

4G6 ENGINE - Specifications

1. SPECIFICATIONS SERVICE SPECIFICATIONS Items

Standard value

Limit

Auto-tensioner rod projection length mm

12

-

Auto-tensioner rod pushed-in amount [when pushed with a force of 98 - 196 N] mm

1.0 or less

-

Timing belt

Rocker arms and camshaft 4G63 SOHC

Intake

37.39

36.89

Exhaust

37.14

36.64

4G64 SOHC

Intake

37.39

36.89

Exhaust

36.83

36.33

Lash adjuster leak down time [diesel fuel at 15 - 20_C] seconds/mm

3 - 20/1.0

-

Camshaft journal outer diameter mm

45

-

Intake

35.79

35.29

Exhaust

37.14

36.64

Lash adjuster leak down time [diesel fuel at 15 - 20_C] seconds/mm

3 - 20/1.0

-

Camshaft journal outer diameter mm

26

-

Cylinder head flatness of gasket surface mm

Less than 0.05

0.2

Cylinder head grinding limit of gasket surface mm Total resurfacing depth of both cylinder head and cylinder block

-

0.2

SOHC

120

-

GDI

132

-

-

Maximum 99.4

Intake

1.0

0.5

Exhaust

1.2

0.7

Intake

1.0

0.5

Exhaust

1.5

1.0

Intake

112.30

111.80

Exhaust

114.11

113.61

Intake

105.5

105.0

Exhaust

105.7

105.2

6.0

-

Camshaft cam height mm

Rocker arms and camshaft (GDI) Camshaft cam height mm

Cylinder head and valves

Cylinder head overall height mm

Cylinder head bolt shank length mm Valve thickness of valve head (margin) mm

SOHC

GDI

Valve overall height mm

SOHC

GDI

Valve stem outer diameter mm E Mitsubishi Motors Corporation

Aug. 1998

PWEE9616-A

Revised

11A-1-2


Items

Standard value

Limit

Intake

0.02 - 0.05

0.10

Exhaust

0.03 - 0.07

0.15

Intake

0.02 - 0.05

0.10

Exhaust

0.05 - 0.09

0.15

45_ - 45.5_

-

SOHC

51.0

50.0

GDI

48.3

47.3

SOHC

267/44.2

-

GDI

294/40.0

-

SOHC

2_ or less

Maximum 4_

GDI

1.5_ or less

Maximum 4_

0.9 - 1.3

-

SOHC

6.0

-

GDI

6.6

-

Valve guide projection from cylinder head upper surface mm

SOHC

14.0

-

GDI

19.5

-

Valve stem projection mm

SOHC

49.30

49.80

Intake

49.20

49.70

Exhaust

48.40

48.90

0.05 Oversize diameter

11.05 - 11.07

-


11.25 - 11.27

-


11.50 - 11.52

-


12.05 - 12.07

-


12.25 - 12.27

-


12.50 - 12.52

-

Intake oversize rework dimensions of valve seat hole (SOHC) mm


34.30 - 34.33

-


34.60 - 34.63

-

Intake oversize rework dimensions of valve seat hole (GDI) mm


35.30 - 35.33

-


35.60 - 35.63

-

Exhaust oversize rework dimensions of valve seat hole (SOHC) mm


34.30 - 34.33

-


34.60 - 34.63

-

Exhaust oversize rework dimensions of valve seat hole (GDI) mm


33.30 - 33.33

-


33.60 - 33.63

-

Valve thickness to valve guide clearance mm

SOHC

GDI

Valve face angle mm Valve spring free length mm

Valve spring load/installed height N/mm

Valve spring out-of-squareness

Valve seat valve contact width mm Valve guide inner diameter mm

GDI

Oversize rework dimensions of valve guide hole (SOHC) mm

Oversize rework dimensions of valve guide hole (GDI) mm


Aug. 1998

PWEE9616-A

Revised

11A-1-3

4G6 ENGINE - Specifications Items

Standard value

Limit

Drive gear

0.08 - 0.14

-

Driven gear

0.06 - 0.12

-

78 or more

-

4G63

85.0

-

4G64

86.5

-

No. 1

0.02 - 0.06

0.1

No. 2

0.02 - 0.06

0.1

No. 1

0.25 - 0.35

0.8

No. 2

0.40 - 0.55

0.8

Oil ring side rail

0.10 - 0.40

1.0

Piston pin outer diameter mm

22.0

-

Piston pin press-in load N (Room temperature)

7,350 - 17,200

-

Crankshaft pin oil clearance mm

0.02 - 0.05

0.1

Connecting rod big end side clearance mm

0.10 - 0.25

0.4

Crankshaft end play mm

0.05 - 0.25

0.40

Crankshaft journal outer diameter mm

57.0

-

Crankshaft pin outer diameter mm

45.0

-

Crankshaft journal oil clearance mm

0.02 - 0.04

0.1

Bearing cap bolt shank length mm

-

Maximum 71.1

Piston to cylinder clearance mm

0.02 - 0.04

-

Cylinder block flatness of gasket surface mm

0.05

0.1

Cylinder block grinding limit of gasket surface mm Total resurfacing depth of both cylinder head and cylinder block

-

0.2

4G63

284

-

4G64

290

-

4G63

85.0

-

4G64

86.5

-

0.01

-

Front case, counterbalance shaft and oil pan Oil pump side clearance mm

Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90_C] Piston and connecting rod Piston outer diameter mm

Piston ring side clearance mm

Piston ring end gap mm

Crankshaft, flywheel and drive plate

Cylinder block overall height mm

Cylinder block inner diameter mm

Cylindricity mm


Aug. 1998

PWEE9616-A

Revised

11A-1-4


TORQUE SPECIFICATIONS Items

Nm

Alternator and ignition system Water pump pulley

9

Adjusting bolt

10

Lock bolt

22

Alternator brace

23

Alternator pivot nut

44

Crankshaft pulley

25

Ignition coil (Multipoint fuel injection)

10

Spark plug

25

Distributor (Carburetor)

12

Camshaft position sensing cylinder (Multipoint fuel injection)

22

Camshaft position sensor support (Multipoint fuel injection)

14

Camshaft position sensor (Multipoint fuel injection)

10

Oil level gauge guide

13

Idler pulley bracket (M8) (Vehicle for Hong Kong)

22

Idler pulley bracket (M10) (Vehicle for Hong Kong)

49

Idler pulley (Vehicle for Hong Kong)

49

Intake manifold (GDI) Vacuum pipe and hose (Flange bolt)

11

Vacuum pipe and hose (Bolt, washer assembly)

8.8

Solenoid valve

8.8

Vacuum pipe

11

Throttle body

11

Intake manifold stay (M6)

8.8

Intake manifold stay (M8)

30

Air intake plenum resonator (Flange bolt)

11

Air intake plenum resonator (Bolt, washer assembly)

8.8

EGR valve

23

EGR valve support

23

Intake manifold

19

Timing belt Timing belt cover flange bolt E Mitsubishi Motors Corporation

Aug. 1999

11 PWEE9616-B

Revised

11A-1-5


Nm

Timing belt cover washer bolt

9

Power steering bracket

49

Crankshaft angle sensor (Multipoint fuel injection)

9

Tensioner arm

22

Tensioner puller

48

Auto tensioner

23

Idler pulley

35

Engine support bracket

49

Oil pump sprocket

54

Crankshaft bolt

118

Tensioner “B”

18

Counterbalance shaft sprocket

45

Camshaft sprocket bolt

88

Exhaust manifold (GDI) Exhaust manifold cover

13

Exhaust manifold (M10)

49


29

Engine hanger

11

Fuel and emission parts Carburetor (Carburetor)

17

Fuel vapor separator (Carburetor)

23

Throttle body (Multipoint fuel injection)

18

EGR valve (Except General Export)

22

Injectors and delivery pipe (Multipoint fuel injection)

12

Fuel pressure regulator (Multipoint fuel injection)

9

Fuel part (GDI) Fuel low pressure pipe (M6)

8.8

Fuel low pressure pipe (M8)

18

Fuel pump return nipple

8.8

Clamp A

8.8

Fuel pipe bracket

11

Fuel feed pipe

11


Aug. 1999

PWEE9616-B

Revised

11A-1-6


Items

Nm

Fuel pump

4.9 ® 17 ± 2

Harness bracket

8.8

Fuel return pipe

11

Fuel high pressure regulator

18

Fuel pressure sensor

18

Pump camshaft case

23

Injector holder

22

Delivery pipe and injector assembly

11

Engine hanger

11

Water pump and intake manifold Engine coolant temperature sensor

29

Engine coolant temperature gauge unit

11

Water inlet fitting

13

Thermostat housing

24

Water inlet pipe

13

Water pump

14


14

Intake manifold stay

31

Intake manifold

19

Engine hanger

11

Detonation sensor (Multipoint fuel injection)

23

Water pump and water hose (GDI) Engine coolant temperature sensor

29


11

Water inlet fitting

12

Water outlet fitting

12

Thermostat housing

23

Water inlet pipe

12

Water pump

13

Knock sensor

22

Exhaust manifold Exhaust manifold cover E Mitsubishi Motors Corporation

13

Aug. 1999

PWEE9616-B

Revised

11A-1-7


Nm

Heat protector

13


29


49


13

Rocker arms and camshaft Rocker cover

3.4

Rocker arm shaft

31

Rocker arms and camshafts (GDI) Camshaft position sensor

8.8

Cover

9.8

Camshaft position sensing cylinder

21

Camshaft position sensing support

13

Beam camshaft cap

20

Cylinder head and valves Cylinder head bolt [Tighten to 78 Nm and then completely loosen before finally tightening with above procedure.]

20 + 90_ + 90_

Front case, counterbalance shaft and oil pan Drain plug

39

Oil pan

6.9

Oil level sensor (For Europe)

8.8

Stiffener (For Europe)

21

Oil screen

18

Oil pressure switch (4G63)

19

Oil pressure switch (4G64)

9.8

Relief plug

44

Oil filter bracket

18

Plug

23

Flange bolt

36

Oil pump cover bolt

16

Oil pump cover screw

9.8

Front case

23

Transmission stay (GDI engine)

21


12


Aug. 1999

PWEE9616-B

Revised

11A-1-8


Items

Nm

Oil pan lower

6.9

Baffle plate

6.9

Oil pan upper

6.9

Piston and connecting rod Connecting rod cap

20 + 90_ ® 100_

Crankshaft, flywheel and drive plate Flywheel bolt

132

Drive plate bolt

132

Rear plate

11

Bell housing cover

8.8

Oil seal case bolt

11

Bearing cap bolt

25 + 90_ ® 100_


Aug. 1999

PWEE9616-B

Revised

11A-1-9


NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The tightening method for the bolts is different from the conventional one. Be sure to observe the method described in the text when tightening the bolts. Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly observed. D

D

Areas where the bolts are in use: (1) Cylinder head bolts (2) Main bearing cap bolts (3) Connecting rod cap bolts Tightening method After tightening the bolts to the specified torque, tighten them another 90_ or 180_ (twice 90_). The tightening method varies on different areas. Observe the tightening method described in the text.

SEALANTS Item

Specified sealant

Quantity

Cam position sensor support

Mitsubishi Genuine Part No. MD970389 or equivalent

As required

Engine coolant temperature sensor

3M Nut Locking Part No. 4171 or equivalent

As required


3M ATD Part No. 8660 or equivalent

As required

Thermostat case


As required



As required

Beam camshaft cap


As required

Cylinder head


As required

Oil pressure switch

3M ATD Part No. 8660 or equivalent

As required

Oil pan


As required

Oil seal case


As required


Aug. 1998

PWEE9616-A

Added

11A-1-10


FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket evenly without a break, while observing the correct bead size. The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram tube (Part No. MD970389). Since the RTV hardens as it reacts with the moisture in the atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing. Disassembly The parts assembled with the FIPG can be easily disassembled without use of a special method. In some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces. For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use the special tool to remove the oil pan. Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old sealant remained in the bolt holes. Form-in-Place Gasket Application When assembling parts with the FIPG, you must observe some precautions, but the procedures is very simple as in the case of a conventional precut gasket. Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour) has passed after installation is completed. The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG.


Aug. 1998

PWEE9616-A

Added

4G6 ENGINE (E - W) - Special Tools

11A-2-1

2. SPECIAL TOOLS Tool


Number

Name

Use

MB990767

Crankshaft pulley holder

Holding camshaft sprocket Use with MD998719.

MD990938

Handle

Installation of crankshaft rear oil seal Use with MD998776.

MB991603

Silent shaft bearing puller stopper

Guide stopper for removal and installation of counterbalance shaft rear bearing Use with MD998372.

MB991654

Cylinder head bolt wrench (12)

Removal and installation of cylinder head bolt

MD998162

Plug wrench

Removal and installation of front case cap plug Use with MD998783.

MD998285

Crankshaft front oil seal guide

Guide for installation of crankshaft front oil seal Use with MD998375.

MD998371

Silent shaft bearing puller

Removal of counterbalance shaft front bearing

MD998372

Silent shaft bearing puller

Removal of counterbalance shaft rear bearing

MD998375

Crankshaft front seal installer

Installation of crankshaft front oil seal

Dec. 1996

PWEE9616

11A-2-2 Tool


4G6 ENGINE (E - W) - Special Tools Number

Name

Use

MD998440

Leak down tester

Leak down test of lash adjuster

MD998441

Lash adjuster retainer

Air bleeding of lash adjuster

MD998442

Lash adjuster wire

Air bleeding of lash adjuster

MD998443

Lash adjuster holder

Retainer for holding lash adjuster in rocker arm at time of removal and installation of rocker shaft assembly

MD998705

Silent shaft bearing installer

Installation of counterbalance shaft front and rear bearing

MD998713

Camshaft oil seal installer

Installation of camshaft oil seal

MD998719

Pulley holder pin

Holding camshaft sprocket Use with MB990767.

MD998727

Oil pan remover

Removal of oil pan

MD998735

Valve spring compressor

Removal and installation of valve and related parts

Dec. 1996

PWEE9616

4G6 ENGINE (E - W) - Special Tools Tool


11A-2-3

Number

Name

Use

MD998738

Set screw

Adjustment of timing belt tension

MD998767

Tensioner puller socket wrench

Adjustment of timing belt tension

MD998772

Valve spring compressor

Removal and installation of valve and related parts

MD998774

Valve stem seal installer

Installation of valve stem seal

MD998775

Valve stem seal installer

Installation of valve stem seal

MD998776

Crankshaft rear oil seal installer

Installation of crankshaft rear oil seal Use with MB990938.

MD998778

Crankshaft sprocket puller

Removal of crankshaft sprocket

MD998780

Piston setting tool

Removal and installation of piston pin

MD998781

Flywheel stopper

Holding of flywheel and drive plate

Aug. 1998

PWEE9616-A

Revised

11A-2-4 Tool


4G6 ENGINE (E - W) - Special Tools Number

Name

Use

MD998783

Plug wrench retainer

Removal and installation of front case cap plug

MD998785

Sprocket stopper

Holding silent shaft sprocket

Aug. 1998

PWEE9616-A

Added

11A-3-1

4G6 ENGINE (E - W) - Alternator and Ignition System

3. ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION

8

6 12 Nm

7

25 Nm

10 4

10 Nm

9

3 44 Nm

22 Nm

2 24 Nm

5

9 Nm

25 Nm

1

Removal steps 1. Drive belt 2. Water pump pulley 3. Alternator brace 4. Alternator 5. Crankshaft pulley 6. Spark plug cable 7. Spark plug 8. High tension cable "BA 9. Distributor assembly 10. O-ring


Dec. 1996

PWEE9616

11A-3-2

4G6 ENGINE (E - W) - Alternator and Ignition System

REMOVAL AND INSTALLATION

10 Nm

7

10 Nm

6 9 25 Nm

10

8 11

4 22 Nm 10 Nm

3 14 Nm

44 Nm

r 22 Nm

24 Nm

2 5

9 Nm

25 Nm

1

Removal steps 1. Drive belt 2. Water pump pulley 3. Alternator brace 4. Alternator 5. Crankshaft pulley 6. Spark plug cable


Dec. 1996

7. 8. 9. "AA 10. 11.

PWEE9616

Ignition coil assembly Spark plug Camshaft position sensor Camshaft position sensing support Camshaft position sensing cylinder

11A-3-3

4G6 ENGINE (E - W) - Alternator and Ignition System REMOVAL AND INSTALLATION (GDI)

9.8 Nm

11 25 Nm

12

49 Nm

6

7 9.8 Nm

1

8.8 Nm

22 Nm 23 Nm

5

4

13 Nm

8 9

2

49 Nm

3

25 Nm

10 49 Nm 22 Nm

Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt 5. Water pump pulley 6. Alternator 7. Alternator brace


Aug. 1999

8. Idler pulley bracket (Vehicle for Hong Kong) 9. Idler pulley (Vehicle for Hong Kong) 10. Crankshaft pulley 11. Ignition coil 12. Spark plug

PWEE9616-B

Revised

11A-3-4

4G6 ENGINE (E - W) - Alternator and Ignition System INSTALLATION SERVICE POINTS "AA CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi Genuine equivalent

Part

No.

MD970389

or

"BA DISTRIBUTOR ASSEMBLY INSTALLATION (1) Turn the crankshaft to bring No. 1 cylinder to the top dead center on compression stroke. (2) Align the mating marks on the distributor housing with that of the coupling key.

Stud bolt


Aug. 1998

(3) Install the distributor assembly on the engine while aligning the stud bolt used for securing the distributor with the slot in the mounting flange of the distributor.

PWEE9616-A

Added

11A-3a-1

4G6 ENGINE (E - W) - Intake Manifold (GDI)

3a. INTAKE MANIFOLD (GDI) REMOVAL AND INSTALLATION (SPACE WAGON)

8.8 Nm

8.8 Nm

3

2

11 Nm

11 Nm 8.8 Nm

16 14

4

11 Nm

12 5 11

13

7 1

23 Nm

17

23 Nm

6 8.8 Nm

19 Nm

18

15 10

11 Nm

19

30 Nm 19 Nm

9 8.8 Nm 30 Nm

8

Removal steps 1. Vacuum pipe and hose (1999 model vehicles for Hong Kong) 2. Solenoid valve (1999 model vehicles for Hong Kong) 3. Vacuum pipe and hose (Vehicles for Europe and 2000 model vehicles for Hong Kong) 4. Solenoid valve (Vehicles for Europe and 2000 model vehicles for Hong Kong) 5. Vacuum pipe 6. Throttle body E Mitsubishi Motors Corporation

Aug. 1999

"DA 7. Throttle body gasket "CA 8. Intake manifold stay "BA 9. Air intake plenum resonator 10. Gasket 11. Water hose 12. EGR valve 13. Gasket "AA 14. Hose clamp "AA 15. EGR support "AA 16. Gasket 17. Gasket 18. Intake manifold 19. Gasket PWEE9616-B

Revised

11A-3a-2

4G6 ENGINE (E - W) - Intake Manifold (GDI)

REMOVAL AND INSTALLATION (GALANT)

8.8 Nm 8.8 Nm

1 2 8 11 Nm

9 11 23 Nm

3 4

13

19 Nm

23 Nm

5 10 14

15

12 16 7

19 Nm 30 Nm

11 Nm 8.8 Nm

6

Removal steps 1. Vacuum pipe and hose 2. Solenoid valve 3. Throttle body "DA 4. Throttle body gasket "CA 5. Intake manifold stay "BA 6. Air intake plenum resonator 7. Gasket 8. Water hose E Mitsubishi Motors Corporation

Aug. 1999

9. 10. "AA 11. "AA 12. "AA 13. 14. 15. 16. PWEE9616-B

EGR valve Gasket Hose clamp EGR support Gasket Gasket Intake manifold Gasket Revised

4G6 ENGINE (E - W) - Intake Manifold (GDI) Intake manifold side Cylinder head side

Hose clamp

11A-3a-3

INSTALLATION SERVICE POINTS "AA EGR SUPPORT / HOSE CLAMP / GASKET INSTALLATION (1) Install the gasket, EGR support and hose clamp to the cylinder head in that order and tighten the fasteners temporarily. (2) Install the EGR support assembly to the intake manifold with the gasket attached on the mating surface, and tighten the fasteners to the specified torque. (3) Tighten the fasteners on the cylinder head side to the specified torque. "BA AIR INTAKE PLENUM RESONATOR INSTALLATION (1) Install the mounting bolts on the throttle body side without fail.

"CA INTAKE MANIFOLD STAY INSTALLATION (1) Tighten the fasteners to the specified torque after confirming that the intake manifold stay is in close contact with the air intake plenum resonator and the cylinder block.

Intake manifold stay

Air intake plenum resonator

"DA THROTTLE BODY GASKET INSTALLATION (1) Position the projection as shown in the illustration.

Projection


Aug. 1999

PWEE9616-B

Added

11A-4-1

4G6 ENGINE (E - W) - Timing Belt

4. TIMING BELT REMOVAL AND INSTALLATION (SOHC)

20 45 Nm

18 45 Nm

17

16

14

15

23

18 Nm

5

88 Nm

13 19

22 7

21 9 Nm

22 Nm

1

48 Nm 49 Nm

49 Nm

6

14 Nm

4

3

12

23 Nm

10

11

8

54 Nm

9 35 Nm 118 Nm

11 Nm

2

9 Nm

AA" "KA "JA "IA AC" "HA AD" "GA

Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 3. Power steering bracket 4. Crankshaft position sensor (Multipoint fuel injection) 5. Timing belt 6. Tensioner pulley 7. Tensioner arm 8. Auto tensioner 9. Idler pulley 10. Oil pump sprocket 11. Crankshaft bolt


Aug. 1999

AE"

AF" "FA AG" "EA "DA AH" "CA AI" "AA

PWEE9616-B

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Crankshaft sprocket Flange (Multipoint fuel injection) Flange (Carburetor) Tensioner “B” Timing belt “B” Counterbalance shaft sprocket Spacer Crankshaft sprocket “B” Engine support bracket Camshaft sprocket bolt Camshaft sprocket Timing belt rear cover

Revised

11A-4-2


REMOVAL AND INSTALLATION (GDI) 21 25

22

1

3.4 Nm

6 7

48 Nm

23

26 24

27

23 Nm

8 2

23 Nm

12

11 Nm

13

31

11 Nm

118 Nm 11 Nm

49 Nm

9 Nm

32

5 30

45 Nm

18

3

17

4

18 Nm

88 Nm

28

15

29

10 33 20

48 Nm

8.8 Nm

19 14

9

16

49 Nm

11 54 Nm

AB" "LA "JA "IA AC" "HA AD" "GA AE" AF" "FA AG" "EA

Removal steps 1. Front upper cover 2. Front lower cover 3. Power steering pump bracket stay 4. Power steering bracket 5. Timing belt 6. Tensioner pulley 7. Tensioner arm 8. Auto tensioner 9. Idle pulley 10. Crankshaft position sensor 11. Oil pump sprocket 12. Crankshaft bolt 13. Crankshaft sprocket 14. Flange 15. Tensioner B 16. Timing belt B 17. Counterbalance shaft sprocket


Aug. 1999

"DA 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. "CA 28. AJ" "BA 29. 30. 31. 32. 33.

AH"

PWEE9616-B

Spacer Crankshaft sprocket B Crankshaft key Breather hose PCV hose PCV valve PCV valve gasket Oil filler cap Rocker cover Rocker cover gasket Engine support bracket Camshaft sprocket bolt Camshaft sprocket Timing belt rear right cover Timing belt rear left upper cover Timing belt rear left lower cover Revised


11A-4-3

REMOVAL SERVICE POINTS AA" TIMING BELT REMOVAL (1) Mark belt running direction for reinstallation. NOTE (1) Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part, check front case oil seals, camshaft oil seal and water pump for leaks.

AB" TIMING BELT REMOVAL (1) If the timing belt is to be reused, chalk an arrow mark on the back surface of the belt so that the belt can be reinstalled in the same direction. (2) Place the exhaust camshaft sprocket in a position where the timing mark for No. 1 cylinder is positioned about one tooth before the top dead center of the compression stroke.

Caution D The camshaft sprocket on the exhaust side can turn very easily because of the valve spring tension. Use care not to allow your fingers to get caught by the sprocket.

Timing mark

(3) Loosen the lock nut of the tensioner pulley, then remove the timing belt.

AC" OIL PUMP SPROCKET REMOVAL (1) Remove the plug on the left side of cylinder block. (2) Insert a screwdriver (shank diameter 8 mm) to block the counterbalance shaft. (3) Remove the nut. (4) Remove the oil pump sprocket.


Aug. 1998

PWEE9616-A

Revised

11A-4-4

4G6 ENGINE (E - W) - Timing Belt AD" CRANKSHAFT BOLT LOOSENING (1) Hold the drive plate with the special tool as shown. (2) Remove the crankshaft bolt.

AE" CRANKSHAFT SPROCKET REMOVAL (1) If it is difficult to remove the sprocket, use the special tool.

AF" TIMING BELT “B” REMOVAL (1) Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused.

6EN1322

MD998785


Aug. 1998

NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part check front case oil seals, camshaft oil seal and water pump for leaks.

AG" COUNTERBALANCE SHAFT SPROCKET REMOVAL (1) Set the special tool as shown to prevent the counterbalance shaft sprocket from turning together. (2) Loosen the bolt and remove the sprocket.

PWEE9616-A

Revised


11A-4-5

AH" CRANKSHAFT SPROCKET “B” REMOVAL (1) If it is difficult to remove the sprocket, use the special tool.

AI" CAMSHAFT SPROCKET BOLT LOOSENING (1) Using the special tools shown in the illustration, lock the camshaft sprocket in position. (2) Loosen the camshaft bolt.

AJ" CAMSHAFT SPROCKET BOLT LOOSENING (1) Use a wrench to hold the hexagonal part of the camshaft, and then remove the camshaft sprocket mounting bolt.

INSTALLATION SERVICE POINTS "AA CAMSHAFT SPROCKET BOLT TIGHTENING (1) Using the special tools shown in the illustration, lock the camshaft sprocket in position. (2) Tighten the camshaft sprocket bolt to the specified torque.

"BA CAMSHAFT SPROCKET BOLT TIGHTENING (1) Using a wrench, hold the camshaft at its hexagon and tighten the bolt to the specification.


Aug. 1998

PWEE9616-A

Revised

11A-4-6

4G6 ENGINE (E - W) - Timing Belt "CA ENGINE SUPPORT BRACKET INSTALLATION (1) Coat the bolts illustrated with sealant before tightening. Specified sealant: 3M ATD Part No. 8660 or equivalent

"DA SPACER INSTALLATION (1) Install the spacer with the chamfered end toward the oil seal.

Sharp edge

Counterbalance shaft

MD998785

Timing marks (on front case)

Timing marks

"EA COUNTERBALANCE SHAFT SPROCKET INSTALLATION (1) Install the counterbalance shaft sprocket and screw the bolt. (2) Install special tool MD998785 as shown in the illustration to lock the counterbalance shaft. (3) Tighten the bolt, and then remove the special tool.

"FA TIMING BELT “B” INSTALLATION (1) Align timing marks on the crankshaft sprocket “B” and counterbalance shaft sprocket with the marks on the front case respectively. (2) Install the timing belt “B” on the crankshaft sprocket “B” and counterbalance shaft sprocket. There should be no slack on the tension side.

(3) Make sure that the relationship between the tensioner pulley center and the bolt center is as shown in the illustration.


Aug. 1998

PWEE9616-A

Revised


11A-4-7

(4) Move the tensioner “B” in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of timing belt. In this condition, tighten bolt to secure tensioner “B”. When the bolt is tightened, use care to prevent shaft from turning together. If shaft is turned together, belt will be overtensioned.

(5) Check to ensure that timing marks on sprockets and front case are in alignment. (6) Press with index finger the center of span on the tension side of timing belt “B”. The bolt must deflect 5 - 7 mm.

"GA CRANKSHAFT BOLT TIGHTENING (1) Using the special tool, hold the flywheel or drive plate. (2) Install the crankshaft pulley in position.

"HA OIL PUMP SPROCKET INSTALLATION (1) Insert a Phillips screwdriver (shank diameter 8 mm shaft) through the plug hole on the left side of the cylinder block to block the left counterbalance shaft. (2) Install the oil pump sprocket. (3) Apply a proper amount of engine oil to the bearing surfaces of the nuts. (4) Tighten the nuts to the specified torque. 6EN0564

B

"IA AUTO TENSIONER INSTALLATION (1) If the auto tensioner rod is in its fully extended position, reset it as follows. (2) Clamp the auto-tensioner in the vise with soft jaws. (3) Push in the rod little by little with the vise until the set hole A in the rod is aligned with the hole B in the cylinder.

A

6AE0049


Aug. 1998

PWEE9616-A

Revised

11A-4-8

4G6 ENGINE (E - W) - Timing Belt (4) Insert a wire (1.4 mm in diameter) into the set holes. (5) Unclamp the auto tensioner from the vise.

6AE0050

(6) Install the auto tensioner to front case and tighten to the specified torque. Caution D Leave the wire installed in the auto tensioner.

6EN0350

"JA TENSIONER PULLEY INSTALLATION (1) Install the tensioner pulley in such direction that its two small holes are arranged vertically.

Small holes 6EN1323

"KA TIMING BELT INSTALLATION (1) Check that the timing belt tensioner and spring have been installed in position. (See "JA) (2) Align timing mark on camshaft sprocket with timing mark on cylinder head.

(3) Align timing mark on crankshaft sprocket with timing mark on front case.


Aug. 1998

PWEE9616-A

Revised


11A-4-9

(4) Align the timing mark on oil pump sprocket with its mating mark.

Oil pump sprocket timing marks

6EN1327

Plug

Screwdriver

(5) Remove the plug on cylinder block and insert a Phillips screwdriver (shank diameter 8 mm) through the hole (Engine with counterbalance shafts). If it can be inserted as deep as 60 mm or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm, turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm or more. Keep the screwdriver inserted until installation of timing belt is finished.

6EN1026

(6) Install the timing belt on the crankshaft sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order.

(7) Lift up the tensioner pulley in the direction of arrow and tighten the center bolt. (8) Check that all timing marks are lined up. (9) Remove the screwdriver inserted in step (5) and fit the plug. (10)Give the crankshaft a quarter counterclockwise turn. Then, turn it clockwise until the timing marks are lined up again.

6EN0899

(11)Install the special tools, Socket Wrench and Torque Wrench, on the tensioner pulley, and loosen the tensioner pulley center bolt.

MD998767

NOTE If the special tool is not available, use a commercially available torque wrench that is capable of measuring 0 - 5 Nm.

6EN0900


Aug. 1998

(12)Torque to 3.5 Nm with the torque wrench. (13)Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification. PWEE9616-A

Revised

11A-4-10

4G6 ENGINE (E - W) - Timing Belt (14)After giving two clockwise turns to the crankshaft, let it alone for approx. 15 minutes. Then, make sure that the auto tensioner setting wire moves freely. NOTE If the wire does not move freely, repeat step (10) above until it moves freely. (15)Remove the auto tensioner setting wire.

(16)Measure the distance “A” (between the tensioner arm and auto tensioner body). Standard value: 3.8 - 4.5 mm

Timing mark

"LA TIMING BELT INSTALLATION (1) Place the exhaust side camshaft sprocket in a position where its timing mark is one tooth offset from the timing mark on the rocker cover in the counterclockwise direction. NOTE Even if the timing marks on the sprocket and the rocker cover are brought into alignment, the exhaust camshaft is forced back by the valve spring tension. It is stabilized at a position one tooth before the timing mark.

Timing mark

(2) Align the timing mark on the intake side camshaft sprocket with that on the rocker cover. NOTE Even if the timing marks on the sprocket and the cover are brought into alignment, the intake camshaft is forced to turn one tooth in the clockwise direction by the valve spring tension and stabilized there.

(3) Place the timing mark on the crankshaft sprocket one tooth this side from the mated timing mark as in the case of the camshaft sprocket.


Aug. 1998

PWEE9616-A

Added


11A-4-11

(4) Align the timing mark on oil pump sprocket with its mating mark.

Oil pump sprocket timing marks

6EN1327

Plug

Screwdriver

(5) Remove the plug on cylinder block and insert a Phillips screwdriver (shank diameter 8 mm) through the hole (Engine with counterbalance shafts). If it can be inserted as deep as 60 mm or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm, turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm or more. Keep the screwdriver inserted until installation of timing belt is finished.

6EN1026

(6) Remove the Phillips screwdriver. Place the oil pump sprocket in a position where its timing mark is one tooth offset from the mated timing mark in the counterclockwise direction.

Timing mark

6EN1327

(7) Fit the timing belt over the exhaust side camshaft sprocket, and secure it at the illustrated position using a paper clip.

(8) Turn the intake side camshaft sprocket as shown to a position where its timing mark is one tooth offset from the mated timing mark in the counterclockwise direction. Then, fit the timing belt over the sprocket and secure it with a paper clip. NOTE The intake camshaft will be turned a little clockwise by the valve spring tension and stabilized in position even if the belt is clipped at one tooth offset position. E Mitsubishi Motors Corporation

Aug. 1998

PWEE9616-A

Added

11A-4-12

4G6 ENGINE (E - W) - Timing Belt (9) Check to ensure that the timing marks on the intake camshaft sprocket side are in alignment when the exhaust camshaft sprocket is turned clockwise to align the timing marks.

17 cogs

NOTE The timing belt span between the intake and exhaust sprockets will have 17 cogs.

Timing mark

(10)Fit the timing belt over the idler pulley, oil pump sprocket and crankshaft sprocket in this order. NOTE Be careful that the belt does not become slack.

Crankshaft sprocket

Oil pump sprocket

(11)Fit the timing belt over the tensioner pulley. NOTE When fitting the timing belt over the tensioner pulley, turn the intake side camshaft sprocket a little counterclockwise, as this will facilitate the work.

Crankshaft sprocket

MD998767

(12)Turn the crankshaft pulley a little in the illustrated direction to pull up the timing belt at the idler pulley side. (13)Check to ensure that the timing marks on the crankshaft sprocket, oil pump sprocket and exhaust camshaft sprocket are all offset one tooth from the corresponding timing marks in the counterclockwise direction.

(14)Using the special tool, turn the tensioner pulley in the illustrated direction to strain the timing belt. Then, secure the tensioner temporarily by tightening the retaining bolt lightly. NOTE There must be no slack in the timing belt between the intake and exhaust camshafts. (15)Turn the crankshaft to align the timing mark with the mark for No. 1 cylinder top dead center in the compression stroke.


Aug. 1998

PWEE9616-A

Added


11A-4-13

(16)Set the special tool as shown and screw it in up to the position where the wire inserted in the auto-tensioner when installing it can be moved lightly.

MD998738

(17)Loosen the retaining bolt of the tensioner pulley. Caution D Loosening the retaining bolt can cause the intake and exhaust camshafts to turn, resulting in slackened timing belt. Use care that the timing belt does not come off the sprockets at this time. (18)Pull up the slack of the timing belt by turning the tensioner in illustrated direction using the special tool and a torque wrench (0 - 5 Nm). (19)From this position, turn back the tensioner until the torque wrench reading becomes 3.5 Nm, then secure it by tightening the retaining bolt. (20)Remove the special tool attached in step (16). (21)Rotate the crankshaft clockwise 2 turns. Then, leave it intact 15 minutes. (22)Check to see that the wire inserted when installing the auto-tensioner can be pulled out lightly. If it can be pulled out lightly, the timing belt is being tensioned properly. If so, remove the wire. In addition, check that the rod protrusion from the auto-tensioner meets the standard value, which is also an indication of properly tensioned timing belt.

MD998767

Standard value: 3.8 - 4.5 mm (23)If the wire cannot be removed with a light force, repeat steps (16) through (21) until the proper belt tensioner is obtained.

INSPECTION TIMING BELT Replace belt if any of the following conditions exist. (1) Hardening of back rubber. Back side is glossy without resilience and leaves no indent when pressed with fingernail.


Aug. 1998

PWEE9616-A

Added

11A-4-14

4G6 ENGINE (E - W) - Timing Belt (2) (3) (4) (5)

Cracks Cracks Cracks Cracks

on rubber back. or peeling of canvas. on rib root. on belt sides.

(6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife.

(7) Abnormal wear on teeth. (8) Missing tooth.

12 mm

AUTO TENSIONER (1) Check the auto tensioner for possible leaks and replace as necessary. (2) Check the rod end for wear or damage and replace as necessary. (3) Measure the rod protrusion. If it is out of specification, replace the auto tensioner. Standard value: 12 mm

6EN0161

98 to 196 N Movement

(4) Press the rod with a force of 98 to 196 N and measure its protrusion. (5) If the measured value is 1 mm or more shorter than the value obtained in step (3), replace the auto tensioner.

6EN1033


Aug. 1998

PWEE9616-A

Added

11A-4a-1

4G6 ENGINE (E - W) - Exhaust Manifold (GDI)

4a. EXHAUST MANIFOLD (GDI) REMOVAL AND INSTALLATION

11 Nm

29 Nm

5 4

49 Nm

29 Nm

3

13 Nm

49 Nm 13 Nm

2

Removal steps 1. Exhaust manifold 2. Exhaust manifold 3. Exhaust manifold 4. Exhaust manifold 5. Engine hanger


Aug. 1998

1

cover (Vehicle for Europe) (Vehicle for Europe) (Vehicle for Hong Kong) gasket

PWEE9616-A

Added

11A-5-1

4G6 ENGINE (E - W) - Fuel and Emission Control Parts

5. FUEL AND EMISSION CONTROL PARTS REMOVAL AND INSTALLATION 17 Nm

5

22 Nm

2 6

23 Nm

4

7 8

1 3

Removal steps 1. Fuel hose 2. Fuel hose 3. Fuel vapor separator 4. Water hose 5. Carburetor 6. Gasket 7. EGR valve (For GCC) 8. Gasket (For GCC) E Mitsubishi Motors Corporation

Dec. 1996

PWEE9616

11A-5-2

4G6 ENGINE (E - W) - Fuel and Emission Control Parts

REMOVAL AND INSTALLATION 3 5

22 Nm

12 Nm

9 18 Nm

4

9 Nm

8 12 13 14

1

11 10

2

7

6

Removal steps 1. Throttle body "CA 2. Throttle body gasket 3. EGR valve (With EGR valve) 4. Cover (Without EGR valve) 5. EGR valve gasket 6. Injectors and delivery pipe 7. Insulator


Aug. 1998

"BA 8. 9. 10. "AA 11. 12. 13. 14.

PWEE9616-A

Fuel pressure regulator O-ring Insulator Injectors O-ring Grommet Delivery pipe

Revised

11A-5-3

4G6 ENGINE (E - W) - Fuel and Emission Control Parts REMOVAL AND INSTALLATION

22 Nm

6 12 Nm

4

5

15 13 14 10 9

18 Nm

3 1

12 11

2

9 Nm

8 7

Removal steps 1. Throttle body "CA 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. Fuel hose 6. Fuel return pipe 7. Injectors and delivery pipe 8. Insulator


Aug. 1998

"BA 9. 10. 11. "AA 12. 13. 14. 15.

PWEE9616-A

Fuel pressure regulator O-ring Insulator Injectors O-ring Grommet Delivery pipe

Revised

11A-5-4

4G6 ENGINE (E - W) - Fuel and Emission Control Parts INSTALLATION SERVICE POINTS "AA INJECTORS INSTALLATION (1) Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. (2) Install injector top end. Be careful not to damage O-ring during installation.

Grommet O-ring

1EN0388

"BA FUEL PRESSURE REGULATOR INSTALLATION (1) Apply a small amount of new engine oil to the O-ring. Insert the fuel pressure regulator into the delivery pipe being careful not to damage the O-ring. Caution D Be sure not to let engine oil get into the delivery pipe. (2) Check that the fuel pressure regulator turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the fuel pressure regulator and check the O-ring for damage, and then re-insert it into the delivery pipe and check once again.

GALANT

SPACE WAGON

Projection

Projection


Aug. 1998

"CA GASKET INSTALLATION (1) Position the projection as shown in the illustration.

PWEE9616-A

Added

11A-5a-1

4G6 ENGINE (E - W) - Fuel Part (GDI)

5a. FUEL PART (GDI) REMOVAL AND INSTALLATION (1999 MODEL SPACE WAGON)

26 8.8 Nm

15

6

18 Nm

8.8 Nm

11 Nm

8.8 Nm

2

14 17

8

3

11 Nm

18

11 Nm

7

1

16

11 10 9

8.8 Nm

4.9 Nm ® 17 Nm ± 2 Nm

19

22 21 20

12

18 Nm

11 Nm

4

13 5 23

30

37 34 35 36

22 Nm

24 32

27

33

28

23 Nm

31

29

25

11 Nm

38


Aug. 1999

PWEE9616-B

Revised

11A-5a-2

"FA

"FA "EA

"EA


Removal steps 1. Fuel hose 2. Fuel low pressure pipe 3. O-ring 4. Fuel pump return nipple 5. O-ring 6. Clamp A 7. Fuel pipe bracket 8. Fuel feed pipe 9. Backup ring 10. O-ring 11. Backup ring 12. Fuel pump 13. O-ring 14. Harness bracket 15. Fuel return pipe 16. Backup ring 17. O-ring 18. Backup ring 19. Fuel high pressure regulator


Aug. 1999

"DA 20. 21. 22. "CA 23. 24. 25. 26. 27. 28. "BA 29. 30. 31. 32. "AA 33. "AA 34. "AA 35. "AA 36. 37. 38.

PWEE9616-B

Fuel pressure sensor Backup ring O-ring Pump camshaft case O-ring O-ring Injector harness Washer Injector holder Delivery pipe and injector assembly Insulator Injector washer Injector Corrugated washer Backup ring O-ring Backup ring Delivery pipe Engine hanger

Revised

11A-5a-2a


REMOVAL AND INSTALLATION (2000 MODEL SPACE WAGON and GALANT)

30 8.8 Nm

15

6

18 Nm

8.8 Nm

11 Nm

8.8 Nm

2

14 17

8

3

11 Nm

18 7

11 Nm

1

16

11 10 9

8.8 Nm

26

19

4.9 Nm ® 17 Nm ± 2 Nm

25 24 23 18 Nm

12 11 Nm

22

4

13

21 20

5 27

34

41 38 39 40

18 Nm

22 Nm

28 36

31

37

32

23 Nm

35

33

29

11 Nm

42


Aug. 1999

PWEE9616-B

Added

11A-5a-2b

"FA

"FA "EA

"EA "DA


Removal steps 1. Fuel hose 2. Fuel low pressure pipe 3. O-ring 4. Fuel pump return nipple 5. O-ring 6. Clamp A 7. Fuel pipe bracket 8. Fuel feed pipe 9. Backup ring 10. O-ring 11. Backup ring 12. Fuel pump 13. O-ring 14. Harness bracket 15. Fuel return pipe 16. Backup ring 17. O-ring 18. Backup ring 19. Fuel high pressure regulator 20. Fuel pressure sensor (GALANT and SPACE WAGON for Hong Kong) 21. Backup ring (GALANT and SPACE WAGON for Hong Kong) 22. O-ring (GALANT and SPACE WAGON for Hong Kong)


Aug. 1999

PWEE9616-B

"DA

"CA

"BA

"AA "AA "AA "AA

23. Flange (SPACE WAGON for Europe) 24. Fuel pressure sensor (SPACE WAGON for Europe) 25. Backup ring (SPACE WAGON for Europe) 26. O-ring (SPACE WAGON for Europe) 27. Pump camshaft case 28. O-ring 29. O-ring 30. Injector harness 31. Washer 32. Injector holder 33. Delivery pipe and injector assembly 34. Insulator 35. Injector washer 36. Injector 37. Corrugated washer 38. Backup ring 39. O-ring 40. Backup ring 41. Delivery pipe 42. Engine hanger

Added


11A-5a-3

INSTALLATION SERVICE POINTS "AA BACKUP RING / CORRUGATED WASHER INSTALLATION (1) Attach the backup ring and O-ring to the injector. The thicker backup ring must be so installed that the inside cut surface is directed as shown in the illustration. Cut surface Backup ring

(2) Coat the corrugated washer with white vaseline and install it to the injector as shown. Caution D Always replace the corrugated washer with new one. Reused corrugated washer can cause fuel or gas leaks.

Corrugated washer

Mating marks

Injector gasket

Insulator

"BA DELIVERY PIPE AND INJECTOR ASSEMBLY INSTALLATION (1) Lubricate O-ring in the injector with spindle oil gasoline. (2) Insert the injector straight into the injector mounting hole in the delivery pipe. (3) Turn the injector clockwise and counterclockwise. If it dose not rotate smoothly, remove it to check for damaged O-ring. Damaged O-ring must be replaced with a new one. Reinstall the injector and check for smooth rotation again. (4) Align the mating mark on the injector with that on the delivery pipe. (5) Install the injector gaskets and insulators on the cylinder head. The insulator can drop off easily. Apply vaseline to it before installation so that it may be held in position. (6) Install the delivery pipe and injector assembly onto the cylinder head, tighten the fasteners temporarily. (7) Install the injector holders and the washers to the assembly and tighten the fasteners to the specified torque. Caution D Strictly observe the specified torque. (8) Tighten the fasteners of the delivery pipe and injector assembly to the specified torque in the order given in the illustration.

3

1


2

Aug. 1998

4

PWEE9616-A

Added

11A-5a-4


Grooved

Coupling

Camshaft O-ring

"CA PUMP CAMSHAFT CASE INSTALLATION (1) Lubricate the O-ring (smaller one for oil passage) with vaseline and install it in the pump camshaft case. (2) Apply small amount of engine oil to the O-ring (larger one) in the case. (3) Install the pump camshaft case onto the cylinder head while aligning its coupling with the groove in the camshaft end. NOTE The key of the coupling and the groove in the camshaft end are both arranged offset with respect to the camshaft center. (4) Tighten the pump camshaft case mounting bolts to the specified torque.

Cut surface

"DA FUEL PRESSURE SENSOR INSTALLATION (1) Install the backup ring to the fuel pressure sensor with its inside cut surface in the illustrated direction. (2) Install the fuel pressure sensor straight into the fuel pressure regulator with labeled surface upward. (3) Tighten the fuel pressure sensor mounting bolt to the specified torque.

Backup ring

Backup ring (Mountable in eitherdirection)

O-ring

Cut surface Backup ring


Aug. 1998

"EA FUEL HIGH PRESSURE REGULATOR / FUEL RETURN PIPE INSTALLATION (1) Install the fuel high pressure regulator on the pump camshaft case and tighten the 3 bolts lightly (with somewhat larger torque than finger tight). Tightening to the specification is to be carried out in the step described in "FA. (2) Fit the backup rings and the O-ring on both ends of the fuel return pipe. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration. (3) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel return pipe ends straight in the respective mounting holes of the pressure regulator and the delivery pipe. Be sure to insert the pipe fully to the stop using care not to twist it. (5) Tighten the bolts at both ends of the pipe to the specified torque.

PWEE9616-A

Added

4G6 ENGINE (E - W) - Fuel Part (GDI) Backup ring (Mountable in either direction)

O-ring

Cut surface Backup ring

3

1

4

11A-5a-5

"FA FUEL PUMP / FUEL FEED PIPE INSTALLATION (1) Insert the fuel pump into the mounting hole in the pump camshaft case, and secure it temporarily with 4 bolts (tighten somewhat with a larger torque than finger tight). (2) Fit the backup rings and the O-ring on both ends of the feed pipe. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration. (3) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel feed pipe ends straight in the respective mounting holes of the fuel and the delivery pipe. Be sure to insert the pipe fully to the stop using care not to twist it. (5) Tighten the bolts at ends of the pipe to the specified torque. (6) Tighten the mounting bolts of the fuel pressure regulator to the specified torque.

(7) Using a torque wrench having the minimum scale of 0.5 Nm, tighten the fuel pump mounting bolts in the following order. 1) Tighten the bolts to 4.9 Nm in the order given in the illustration. 2) Tighten the bolts to 17 Nm in the order given in the illustration. The torque variation among 4 bolts must be within 2 Nm. Caution D Strictly observe the specified tightening torque. Deviation from the specification can cause problems such as leakage or the like.

2

(8) Clamp the fuel return pipe and feed pipe using the fuel pipe bracket and clamp A, and tighten them lightly. (9) Secure the fuel pipe bracket to the cam cap temporarily. (10)Tighten the bolts which are securing the pipes temporarily to the specified torque. (11)Tighten the bolts on the beam cam shaft side which have been temporarily tightened to the specified torque.


Aug. 1998

PWEE9616-A

Added

11A-6-1

4G6 ENGINE (E - W) - Water Pump and Intake Manifold

6. WATER PUMP AND INTAKE MANIFOLD REMOVAL AND INSTALLATION 13 Nm 24 Nm

1

6

15 11 Nm

3

4 5 13 Nm

14

20 Nm

8

2 7 16

8

31 Nm

11 17 12 Nm

14 Nm

10

12 9 13

14 Nm

"CA

"BA "AA "AA

Removal steps 1. Water hose 2. Water hose 3. Engine coolant temperature gauge unit 4. Water inlet fitting 5. Thermostat 6. Thermostat housing 7. Water inlet pipe 8. O-ring


Dec. 1996

9. 10. 11. 12. 13. 14. 15. 16. 17.

PWEE9616

Water pump Water pump gasket Oil level gauge Oil level gauge guide O-ring Intake manifold stay Intake manifold Intake manifold gasket Engine hanger

11A-6-2

4G6 ENGINE (E - W) - Water Pump and Intake Manifold

REMOVAL AND INSTALLATION 13 Nm 24 Nm

16

7

1 11 Nm

4

5

17

6

19 Nm 13 Nm

2 9

15

29 Nm

8 3

9

31 Nm

19

23 Nm

12 18 11 Nm

14 Nm

11

13 10 14

14 Nm

"DA "CA

"BA "AA "AA

Removal steps 1. Water hose 2. Water hose 3. Engine coolant temperature sensor 4. Engine coolant temperature gauge unit 5. Water inlet fitting 6. Thermostat 7. Thermostat housing 8. Water inlet pipe 9. O-ring


Aug. 1998

PWEE9616-A

10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Water pump Water pump gasket Oil level gauge Oil level gauge guide O-ring Intake manifold stay Intake manifold Intake manifold gasket Engine hanger Detonation sensor

Revised

11A-6-3

4G6 ENGINE (E - W) - Water Pump and Intake Manifold REMOVAL AND INSTALLATION 3 13 Nm 24 Nm

8 1 11 Nm

17

5 7

6

18 2

13 Nm

19 Nm

29 Nm

10 9

4

10

16 31 Nm

19 13 11 Nm

11 14 Nm

14 12 15

14 Nm

"DA "CA

"BA "AA

Removal steps 1. Water hose 2. Water hose 3. Water hose 4. Engine coolant temperature sensor 5. Engine coolant temperature gauge unit 6. Water inlet fitting 7. Thermostat 8. Thermostat housing 9. Water inlet pipe


Aug. 1998

PWEE9616-A

"AA 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

O-ring Water pump Water pump gasket Oil level gauge Oil level gauge guide O-ring Intake manifold stay Intake manifold Intake manifold gasket Engine hanger

Revised

11A-6-4

4G6 ENGINE (E - W) - Water Pump and Intake Manifold INSTALLATION SERVICE POINTS

Water pipe

"AA WATER PIPE / O-RING INSTALLATION (1) Wet the O-ring (with water) to facilitate assembly. Caution D Keep the O-ring free of oil or grease.

O-ring

6EN0594

"BA SEALANT APPLICATION TO THERMOSTAT HOUSING Specified sealant: Mitsubishi Genuine equivalent

3 mm diameter bead sealant

6EN1168

Part

No.

MD970389

or

NOTE (1) Be sure to install the housing quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx. 1 hour. "CA SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant: 3M ATD Part No. 8660 or equivalent

9EN0092

"DA SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant: 3M Nut Locking Part No. 4171 or equivalent

9EN0091


Aug. 1998

PWEE9616-A

Added

11A-6a-1

4G6 ENGINE (E - W) - Water Pump and Water Hose (GDI)

6a. WATER PUMP AND WATER HOSE (GDI) REMOVAL AND INSTALLATION 12 Nm 11 Nm

7

2

29 Nm

4 23 Nm

3

1 9

6

12 Nm

8 5 13

10 12 Nm

22 Nm

9

11

12

13 Nm

Removal steps 1. Water hose "EA 2. Water hose 3. Engine coolant temperature sensor "DA 4. Engine coolant temperature gauge unit 5. Water inlet fitting 6. Thermostat


Aug. 1998

PWEE9616-A

"CA "BA "AA "AA

7. 8. 9. 10. 11. 12. 13.

Water outlet fitting Thermostat housing O-ring Water inlet pipe Water pump Gasket Knock sensor

Added

11A-6a-2

4G6 ENGINE (E - W) - Water Pump and Water Hose (GDI) INSTALLATION SERVICE POINTS "AA O-RING / WATER INLET PIPE INSTALLATION (1) Replace the O-ring of the water inlet pipe, and then apply water to the O-ring to make installation easy. Caution D Never apply any oil or grease to the O-ring. D Secure the water pipe after the thermostat case has been reinstalled.

"BA THERMOSTAT CASE INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine equivalent

Part

No.

MD970389

or

"CA WATER OUTLET FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine equivalent

Part

No.

MD970389

or

"DA ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION (1) Apply the specified sealant to the threads. Specified sealant: 3M ATD Part No. 8660 or equivalent

9EN0092

"EA ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION (1) When reusing the sensor, apply the specified sealant to the threads. Specified sealant: 3M Nut Locking Part No. 4171 or equivalent

9EN0091


Aug. 1998

PWEE9616-A

Added

11A-7-1

4G6 ENGINE (E - W) - Exhaust Manifold

7. EXHAUST MANIFOLD REMOVAL AND INSTALLATION (GALANT)

1 13 Nm

6 29 Nm

4 13 Nm

49 Nm

2 5

13 Nm

13 Nm

3 13 Nm

Removal steps "AA 1. Water outlet fitting 2. Heat protector (Multipoint fuel injection) 3. Exhaust manifold cover (Carburetor) 4. Engine hanger 5. Exhaust manifold 6. Exhaust manifold gasket


Aug. 1998

PWEE9616-A

Revised

11A-7-2

4G6 ENGINE (E - W) - Exhaust Manifold

REMOVAL AND INSTALLATION (SPACE WAGON)

1 13 Nm

5 29 Nm

3

49 Nm

2 13 Nm

4

Removal steps "AA 1. Water outlet fitting 2. Exhaust manifold cover 3. Engine hanger 4. Exhaust manifold 5. Exhaust manifold gasket

INSTALLATION SERVICE POINTS "AA SEALANT APPLICATION TO WATER OUTLET FITTING

3 mm diameter bead sealant

Specified sealant: Mitsubishi Genuine equivalent

6EN1170


Aug. 1998

Part

No.

MD970389

or

NOTE (1) Be sure to install the water outlet fitting quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx. 1 hour.

PWEE9616-A

Revised

4G6 ENGINE (E - W) - Rocker Arms and Camshaft

11A-8-1

8. ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation.

1

2 3 3.4 Nm

4

5 6

31 Nm

13 8 12 12 12

11

11

10

11

16

10

12 11

10

15

10

15

14

15

17

18

15 9

7

Removal steps 1. Breather hose 2. P.C.V. hose 3. Oil filler cap 4. Rocker cover 5. Rocker cover gasket 6. Oil seal "CA 7. Oil seal AA" "BA 8. Rocker arms and rocker arm shaft AA" "BA 9. Rocker arms and rocker arm shaft E Mitsubishi Motors Corporation

Aug. 1998

PWEE9616-A

"BA 10. 11. 12. 13. "AA 14. 15. 16. "AA 17. 18.

Rocker shaft spring Rocker arm A Rocker arm B Rocker arm shaft (Intake side) Lash adjuster Rocker arm C Rocker arm shaft (Exhaust side) Lash adjuster Camshaft

Revised

11A-8-2

4G6 ENGINE (E - W) - Rocker Arms and Camshaft REMOVAL SERVICE POINT AA" ROCKER ARMS AND ROCKER ARM SHAFTS REMOVAL Caution D If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8-3.) (1) Set special tool MD998443 to prevent the lash adjuster from coming free and falling to the floor.

INSTALLATION SERVICE POINTS "AA LASH ADJUSTER INSTALLATION (1) Insert the lash adjuster to rocker arm, being careful not to spill the diesel fuel. Then use the special tool to prevent adjuster from falling while installing it. Caution D If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8-3.)

"BA ROCKER SHAFT SPRING / ROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION (1) Temporarily tighten the rocker shaft with the bolt so that all rocker arms on the inlet valve side do not push the valves. (2) Fit the rocker shaft spring from the above and position it so that it is right angles to the plug guide. NOTE Install the rocker shaft spring before installing the exhaust side rocker arms and rocker arm shaft. (3) Remove the special tool for securing the lash adjuster. (4) Make sure that the notch in the rocker arm shaft is in the direction as illustrated.

"CA CAMSHAFT OIL SEAL INSTALLATION MD998713


Aug. 1998

PWEE9616-A

Revised


11A-8-3

INSPECTION CAMSHAFT (1) Measure the cam height. Item GALANT SPACE WAGON

Standard value mm

Limit mm

Intake

37.39

36.89

Exhaust

37.14

36.64

Intake

37.39

36.89

Exhaust

36.83

36.33

ROCKER ARM (1) Check the roller surface. If any dents, damage or seizure is evident, replace the rocker arm. (2) Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace the rocker arm. (3) Check the inside diameter. If damage or seizure is evident, replace the rocker arm. Roller tip

LASH ADJUSTERS Caution D The lash adjusters are precision-engineered mechanisms. Do not allow them to become contaminated by dirt or other foreign substances. D Do not attempt to disassemble the lash adjusters. D Use only fresh diesel fuel to clean the lash adjusters.

Outside cleaning

A

Inside cleaning

B

Filling with diesel fuel

(1) Prepare three containers and approximately five liters of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing upright. Then, perform the following steps with each lash adjuster.

C

(2) Place the lash adjuster in container A and clean its outside surface. NOTE Use a nylon brush if deposits are hard to remove.


Aug. 1998

PWEE9616-A

Revised

11A-8-4

4G6 ENGINE (E - W) - Rocker Arms and Camshaft (3) Fit special tool MD998441 onto the lash adjuster. (4) While gently pushing down the internal steel ball using special tool MD998442, move the plunger through 5 to 10 strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil.

MD998441

Diesel fuel

MD998442

Caution D The steel ball spring is extremely weak, so the lash adjuster’s functionality may be lost if the air bleed wire is pushed in hard. NOTE If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster.

(5) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber.

MD998442 Diesel fuel

(6) Fit special tool MD998441 onto the lash adjuster. (7) Place the lash adjuster in container B. Then, gently push down the internal steel ball using special tool MD998442 and move the plunger through 5 to 10 strokes until it slides smoothly. This operation will clean the lash adjuster’s pressure chamber.

MD998441

Diesel fuel

MD998442

Caution D The steel ball spring is extremely weak, so the lash adjuster’s functionality may be lost if the air bleed wire is pushed in hard. (8) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber.

MD998442 Diesel fuel E Mitsubishi Motors Corporation

Aug. 1998

PWEE9616-A

Revised


11A-8-5

(9) Place the lash adjuster in container C. Then, gently push down the internal steel ball using special tool MD998442.

MD998442

Diesel fuel

MD998441

Caution D Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when the chamber is filled with diesel fuel.

(10)Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill diesel fuel. (11)Remove special tool MD998441.

MD998442


(12)Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjuster’s height matches that of a new lash adjuster. NOTE If lash adjuster contracts, perform the operations (9) through (12) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.

MD998440

Division = 1 mm

Lash adjuster

(13)Set the lash adjuster on the special tool MD998440 (leak down tester). (14)After the plunger has moved downward slightly (0.2 to 0.5 mm), measure the time taken for it to move downward by a further 1 mm. Standard value: 3 - 20 seconds/1 mm [with diesel fuel at 15 20_C (59 - 68_F)] NOTE Replace the lash adjuster if the time measurement is out of specification.


Aug. 1998

PWEE9616-A

Added

11A-8-6


MD998442


(15)Fit special tool MD998441 onto the lash adjuster. (16)Place the lash adjuster in container C again, then gently push down the internal steel ball using special tool MD998442. (17)Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel. (18)Remove special tool MD998441. (19)Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjuster’s height matches that of a new lash adjuster. NOTE If lash adjuster contracts, perform the operations (15) through (19) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps. (20)Stand the lash adjuster upright to prevent diesel fuel spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible.


Aug. 1998

PWEE9616-A

Added

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI)

11A-8a-1

8a. ROCKER ARMS AND CAMSHAFTS (GDI) REMOVAL AND INSTALLATION

20 Nm

7 Apply engine oil to all moving parts before installation.

8 9 10

9.8 Nm

2 3 5

6

11

21 Nm

12

4

1 8.8 Nm 13 Nm

Removal steps 1. Camshaft position sensor 2. Cover 3. Gasket "DA 4. Camshaft position sensing cylinder "CA 5. Camshaft position sensing cylinder support "BA 6. Oil seal


Aug. 1998

7. 8. 9. 10. 11. AA" "AA 12.

PWEE9616-A

"BA "BA "BA "BA

Beam camshaft cap Beam camshaft cap gasket Intake camshaft Exhaust camshaft Rocker arm Lash adjuster

Added

11A-8a-2

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) REMOVAL SERVICE POINTS AA" LASH ADJUSTER REMOVAL Caution D If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8a-4.)

INSTALLATION SERVICE POINTS "AA LASH ADJUSTER INSTALLATION Caution D If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8a-4.) (1) Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out.

"BA BEAM CAMSHAFT CAP GASKET / BEAM CAMSHAFT CAP / CAMSHAFT / OIL SEAL INSTALLATION (1) Locate the camshaft dowel pins as illustrated.

Dowel pin Approx. 11_

Timing belt side

3 mm

(2) Apply a 3 mm thick continuous bead of sealant to the bottom surface of the beam camshaft cap along the groove. Specified sealant: Mitsubishi genuine equivalent

Part

No.

MD970389

or

Beam camshaft cap

(3) Apply sealant to the illustrated position of the cylinder head upper surface.

Timing belt side

Specified sealant: Mitsubishi genuine equivalent

Part

No.

MD970389

or

(4) Install the beam camshaft cap gasket.


Aug. 1998

PWEE9616-A

Added


11A-8a-3

(5) Install the beam camshaft cap before the sealant applied becomes dry and hard. (6) Tighten the bolts to the specified torque in the order shown in the illustration. Specified torque: 20 Nm

Timing belt side

MD998713

(7) Install the camshaft oil seal before the sealant applied becomes dry and hard. (8) Wipe off squeezed out excess sealant from the circumference of the beam camshaft cap.

"CA CAMSHAFT POSITION SENSING CYLINDER SUPPORT INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi genuine equivalent

Part

No.

MD970389

or

"DA CAMSHAFT POSITION SENSING CYLINDER INSTALLATION (1) Set the No. 1 cylinder to the compression top dead center position (so that dowel pin of the exhaust camshaft is at the top). (2) Install the camshaft position sensing cylinder so that the white paint mark is facing in the direction shown in the illustration.

Paint mark

Camshaft position sensor

INSPECTION CAMSHAFT (1) Measure the cam height. Standard value: Intake 35.79 mm Exhaust 37.14 mm Limit: Intake Exhaust E Mitsubishi Motors Corporation

Aug. 1998

PWEE9616-A

35.29 mm 36.64 mm Added

11A-8a-4

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) LASH ADJUSTER Caution D The lash adjusters are precision-engineered mechanisms. Do not allow them to become contaminated by dirt or other foreign substances. D Do not attempt to disassemble the lash adjusters. D Use only fresh diesel fuel to clean the lash adjusters.

Outside cleaning

A

Inside cleaning

B

Filling with diesel fuel

(1) Prepare three containers and approximately five liters of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing upright. Then, perform the following steps with each lash adjuster.

C

(2) Place the lash adjuster in container A and clean its outside surface. NOTE Use a nylon brush if deposits are hard to remove.

Diesel fuel

(3) While gently pushing down the internal steel ball using special tool MD998442, move the plunger through 5 to 10 strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil.

MD998442

Diesel fuel

Caution D The steel ball spring is extremely weak, so the lash adjuster’s functionality may be lost if the air bleed wire is pushed in hard. NOTE If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster.


Aug. 1998

PWEE9616-A

Added


11A-8a-5

(4) Removal the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber.

MD998442

Caution D Make sure the oil hole in the side of the body is pointing toward container A. Do not point the oil hole at yourself or other people.

Diesel fuel

(5) Place the lash adjuster in container B. Then, gently push down the internal steel ball using special tool MD998442 and move the plunger through 5 to 10 strokes until it slides smoothly. This operation will clean the lash adjuster’s pressure chamber.

Diesel fuel

MD998442

Caution D The steel ball spring is extremely weak, so the lash adjuster’s functionality may be lost if the air bleed wire is pushed in hard.

(6) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber.

MD998442

Caution D Make sure the oil hole in the side of the body is pointing toward container A. Do not point the oil hole at yourself or other people.

Diesel fuel

(7) Place the lash adjuster in container C. Then, gently push down the internal steel ball using special tool MD998442. Caution D Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when chamber is filled with diesel fuel. MD998442

Diesel fuel

(8) Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.

MD998442

Diesel fuel


Aug. 1998

PWEE9616-A

Added

11A-8a-6

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) (9) Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjuster’s height matches that of a new lash adjuster. NOTE If lash adjuster contracts, perform the operations (7) through (9) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.

MD998440

Division = 1 mm

(10)Set the lash adjuster on the special tool MD998440 (leak down tester).

Lash adjuster

Lash adjuster

MD998442


Nut

(11)Remove the bolt from the tester, then adjust the height as illustrated. (12)After the plunger has moved downward slightly measure the time taken for it to move downward by a further 1 mm. Standard value: 3 - 20 second/1 mm [with diesel fuel at 15 - 20_C (59 - 68_F)]

Diesel fuel

Aug. 1998

NOTE Replace the lash adjuster if the time measurement is out of specification. (13)Place the lash adjuster in container C again, then gently push down the internal steel ball using special tool MD998442. (14)Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.

PWEE9616-A

Added


11A-8a-7

(15)Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check the lash adjuster’s height matches that of a new lash adjuster.

MD998442

Diesel fuel

NOTE If lash adjuster contracts, perform the operations (13) through (15) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps. (16)Stand the lash adjuster upright to prevent diesel fuel from spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible.


Aug. 1998

PWEE9616-A

Added

11A-9-1

4G6 ENGINE (E - W) - Cylinder Head and Valves

9. CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION (SOHC)

1

2

8

20

9 10

4

14

5

15

6

17

12 13 16

19 11

18 7 3

Apply engine oil to all moving parts before installation.

AA" "EA "DA AB" "CA "BA AB" "CA "BA

Removal steps 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket 4. Retainer lock 5. Valve spring retainer 6. Valve spring 7. Intake valve 8. Retainer lock 9. Valve spring retainer 10. Valve spring


Aug. 1998

11. AC" "AA 12. 13. AC" "AA 14. 15. 16. 17. 18. 19. 20.

PWEE9616-A

Exhaust valve Valve stem seal Valve spring seat Valve stem seal Valve spring seat Intake valve guide Exhaust valve guide Intake valve seat Exhaust valve seat Cylinder head

Revised

11A-9-2


REMOVAL AND INSTALLATION (GDI) 8

1

9 10

4 5 6

14

20

15 17

12 13 19 16

11 18 7 3

2


AA" "EA AB" "CA "BA AB" "CA "BA

Removal steps 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket 4. Retainer lock 5. Valve spring retainer 6. Valve spring 7. Intake valve 8. Retainer lock 9. Valve spring retainer 10. Valve spring


Aug. 1998

11. AC" "AA 12. 13. AC" "AA 14. 15. 16. 17. 18. 19. 20.

PWEE9616-A

Exhaust valve Valve stem seal Valve spring seat Valve stem seal Valve spring seat Intake valve guide Exhaust valve guide Intake valve seat Exhaust valve seat Cylinder head

Revised


11A-9-3

REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS Keep removed parts in order according to the cylinder number and intake/exhaust.

MB991654

AA" CYLINDER HEAD BOLTS REMOVAL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. 9EN0061

MB991654

MD998772

AB" RETAINER LOCK REMOVAL (1) Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location for reassembly.

9EN0062

MD998772


Aug. 1998

PWEE9616-A

Revised

11A-9-4

4G6 ENGINE (E - W) - Cylinder Head and Valves AC" VALVE STEM SEAL REMOVAL (1) Do not reuse removed stem seal.

INSTALLATION SERVICE POINTS "AA VALVE STEM SEAL INSTALLATION (1) Install the valve spring seat. (2) The special tool must be used to install the valve stem seal. Improper installation could result in oil leaks past the valve guide. MD998774

Caution D Do not reuse removed valve stem seals.

9EN0065

MD998737

"BA VALVE SPRING INSTALLATION (1) Direct the valve spring end with identification color toward the spring retainer.


Aug. 1998

PWEE9616-A

Revised

4G6 ENGINE (E - W) - Cylinder Head and Valves MD998772

11A-9-5

"CA RETAINER LOCK INSTALLATION (1) The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and damage, the stem seal.

9EN0062

MD998772

"DA CYLINDER HEAD GASKET IDENTIFICATION Identification mark: 4G63N

"EA CYLINDER HEAD BOLT INSTALLATION (1) When installing the cylinder head bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolt. Limit: Max. 99.4 mm (2) Apply engine oil to the bolt threads and to the washers. Shank length 6EN0782

(3) Using the special tool (MB991654) and according to the tightening sequence, tighten the bolts to the specified torque.

Timing belt side

Tightening torque: 78 Nm (4) Loosen all bolts fully. (5) Retighten the loosened bolts to a torque of 20 Nm in the specified tightening sequence.


Aug. 1998

PWEE9616-A

Revised

11A-9-6

4G6 ENGINE (E - W) - Cylinder Head and Valves (6) Make paint marks on the cylinder head bolt heads and cylinder head. (7) Give a 90_ turn to the cylinder head bolts in the specified tightening sequence. (8) Give another 90_ turn to the cylinder head bolts and make sure that the paint mark on the head of each cylinder head bolt and that on the cylinder head are on the same straight line.

90_

90_ Paint mark 6AE0297

Caution D If the bolt is turned less than 90_, proper fastening performance may not be expected. When tightening the bolt, therefore, be careful to give a sufficient turn to it. D If the bolt is overtightened, loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1).

INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.05 mm Limit: 0.2 mm (2) If the service limit is exceeded, correct to meet specification. 9EN0064

Grinding limit: *0.2 mm * Includes combined with cylinder block grinding. Cylinder head height (Specification when new): SOHC 119.9 - 120.1 mm GDI 131.9 - 132.1 mm


Aug. 1998

PWEE9616-A

Revised

11A-9-7


VALVE (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer. Valve seat contact should be maintained uniform at the center of valve face. (2) If the margin exceeds the service limit, replace the valve. Item SOHC GDI

Standard value mm

Limit mm

Intake

1.0

0.5

Exhaust

1.2

0.7

Intake

1.0

0.5

Exhaust

1.5

1.0

(3) Measure valve’s total length. If measurement is less than specified, replace the valve. Item SOHC GDI

Limit mm

Intake

112.30

111.80

Exhaust

114.11

113.61

Intake

105.5

105.0

Exhaust

105.7

105.2

VALVE SPRING (1) Measure the free height of spring and, if it is smaller than the limit, replace.

Out of square

Free height

1EN0264


Standard value mm

Aug. 1998

Item

Standard value mm

Limit mm

SOHC

51.0

50.0

GDI

48.3

47.3

(2) Measure the squareness of the spring and, if the limit is exceeded, replace. Item

Standard value mm

Limit mm

SOHC

2_

4_

GDI

1.5_

4_

PWEE9616-A

Added

11A-9-8

4G6 ENGINE (E - W) - Cylinder Head and Valves VALVE GUIDE (1) Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both.

Valve guide

Item SOHC GDI

Valve stem end Valve stem projection Spring seating surface

DEN0212

Standard value mm

Limit mm

Intake

0.02 - 0.05

0.10

Exhaust

0.03 - 0.07

0.15

Intake

0.02 - 0.05

0.10

Exhaust

0.05 - 0.09

0.15

VALVE SEAT (1) Assemble the valve, then measure the valve stem projection between the end of the valve stem and the spring seating surface. If the measurement exceeds the specified limit, replace the valve seat. Item SOHC GDI

Standard value mm

Limit mm

Intake

49.30

49.80

Exhaust

49.30

49.80

Intake

49.20

49.70

Exhaust

48.40

48.90

VALVE SEAT RECONDITIONING PROCEDURE 0.9 - 1.3 mm

43.5_ - 44_

(1) Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve guide. (2) Using the seat grinder, correct to obtain the specified seat width and angle. (3) After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection (refer to VALVE SEAT in INSPECTION).

6EN0491


Aug. 1998

PWEE9616-A

Added


11A-9-9

VALVE SEAT REPLACEMENT PROCEDURE

0.5 - 1 mm

(1) Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat.

0.5 - 1 mm

(2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. Valve seat ring hole diameter Height of seat ring

Item SOHC

Standard value mm Intake Exhaust

Oversize I.D. 1EN0275

GDI

Intake Exhaust

0.30 O.S.

34.30 - 34.33

0.60 O.S.

34.60 - 34.63

0.30 O.S.

31.80 - 31.83

0.60 O.S.

32.60 - 32.63

0.30 O.S.

35.30 - 35.33

0.60 O.S.

35.60 - 35.63

0.30 O.S.

33.30 - 33.33

0.60 O.S.

33.60 - 33.63

(3) Before fitting the valve seat, either heat the cylinder head up to approximately 250_C (482_F) or cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from galling. (4) Using a valve seat cutter, correct the valve seat to the specified width and angle. See “VALVE SEAT RECONDITIONING PROCEDURE”.


Aug. 1998

PWEE9616-A

Added

11A-9-10

4G6 ENGINE (E - W) - Cylinder Head and Valves VALVE GUIDE REPLACEMENT PROCEDURE (1) Force the valve guide out toward the cylinder block using a press. (2) Machine the valve guide hole in the cylinder head to the size of the oversize valve guide to be installed. Caution D Do not use the valve guide of the same size as the removed one. Valve gauge hole diameters in cylinder head Item SOHC

GDI

Standard value mm 0.05 O.S.

11.05 - 11.07

0.25 O.S.

11.25 - 11.27

0.50 O.S.

11.50 - 11.52

0.05 O.S.

12.05 - 12.07

0.25 O.S.

12.25 - 12.27

0.50 O.S.

12.50 - 12.52

(3) Press-fit the valve guide until it protrude specified value (SOHC 14 mm, GDI 19.5 mm) as shown in the illustration. Caution D Press the valve guide from the cylinder head top surface. D Valve guide for intake valve and that for exhaust valve are different in length. (45.5 mm for intake valve; 50.5 mm for exhaust valve) Protrusion 1EN0106


Aug. 1998

(4) After the valve guide has been installed, insert a new valve to check for smooth sliding motion.

PWEE9616-A

Added

4G6 ENGINE (E - W) -

11A-10-1

Front Case, Counterbalance Shafts and Oil Pan

10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN REMOVAL AND INSTALLATION 33

19 Nm

31

13 Apply engine oil to all moving parts before installation.

30

(4G63)

32

21 18 (SOHC)

20 23 Nm 9.8 Nm

23 Nm

23

18 (GDI) 19

9

22

28

21 Nm

24 8

27 7

16 Nm

18 Nm

25 17 16

(4G64)

13

26

10 11 15

39 Nm 23 Nm

3

2

36 Nm

23 Nm

6

18 Nm

12

14

29

5

4 8.8 Nm

1 9.8 Nm

6.9 Nm 44 Nm 21 Nm

"OA "NA

AA" "LA

AD" "KA AE" "JA "IA

Removal steps 1. Oil filter 2. Drain plug 3. Drain plug gasket 4. Oil level sensor (Vehicle for Europe) 5. Transmission stay (GDI engine) 6. Oil pan 7. Oil screen 8. Oil screen gasket 9. Stiffener (SOHC engine - vehicle for Europe) 10. Plug 11. O-ring 12. Flange bolt 13. Oil pressure switch 14. Relief plug 15. Relief plug gasket 16. Relief spring 17. Relief plunger


Aug. 1999

"HA "GA "GA "FA "EA "DA

AF" "CA AG" "BA AG" "AA

PWEE9616-B

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

Oil filter bracket Oil filter bracket gasket Front case assembly Front case gasket Oil pump cover Oil pump driven gear Oil pump drive gear Crankshaft front oil seal Oil pump oil seal Counterbalance shaft oil seal Front case Counterbalance shaft, left Counterbalance shaft, right Counterbalance shaft front bearing Counterbalance shaft rear bearing, left 33. Counterbalance shaft rear bearing, right Revised

11A-10-2



REMOVAL AND INSTALLATION 34 32 31


33

22 21

23 Nm

9.8 Nm

23 Nm 18 Nm

30

23

29

6.9 Nm

24 25

20

10 9

28

19

7 6

16 Nm

26

18 Nm

27

13 18 17 14

11 12 16 15

23 Nm

3

36 Nm 23 Nm

5 12 Nm

39 Nm

1 9.8 Nm

6.9 Nm

2

4

6.9 Nm

8

44 Nm

21 Nm

"OA "NA AB" "MA AC" "MA AD" "KA AE" "JA "IA

Removal steps 1. Oil filter 2. Drain plug 3. Drain plug gasket 4. Transmission stay 5. Oil level gauge guide 6. Oil pan lower 7. Baffle plate 8. Oil pan upper 9. Oil screen 10. Gasket 11. Plug 12. O-ring 13. Flange bolt 14. Oil pressure switch 15. Relief plug 16. Gasket 17. Relief spring 18. Relief plunger


Aug. 1998

"HA "GA "GA "FA "EA "DA

AF" "CA AG" "BA AG" "AA

PWEE9616-A

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.

Oil filter bracket Oil filter bracket gasket Front case assembly Gasket Oil pump cover Oil pump driven gear Oil pump drive gear Crankshaft front oil seal Oil pump oil seal Counterbalance shaft oil seal Front case Counterbalance shaft, left Counterbalance shaft, right Counterbalance shaft front bearing Counterbalance shaft rear bearing, left 34. Counterbalance shaft rear bearing, right

Revised

4G6 ENGINE (E - W) MD998727

11A-10-3


REMOVAL SERVICE POINTS AA" OIL PAN REMOVAL (1) Remove all oil pan bolts. (2) Drive in the special tool between the cylinder block and oil pan. NOTE Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil leakage.

6EN0698

AB" OIL PAN LOWER REMOVAL (1) Apply a wood block to the oil pan side and remove the oil pan lower by tapping lightly on it with a plastic hammer. Caution D Do not use a scraper or special tool to remove the oil pan.

AC" OIL PAN UPPER REMOVAL (1) Remove all bolts. (2) Screw a bolt into bolt hole A shown to remove the oil pan.

A

Caution D Do not use a scraper or special tool to remove the oil pan. A

MD998162

AD" PLUG REMOVAL (1) If the plug is too tight, hit the plug head with a hammer two to three times, and the plug will be easily loosened.

MD998783

AE" FLANGE BOLT REMOVAL (1) Remove the plug on the side of cylinder block. (2) Insert a Phillips screwdriver (shank diameter 8 mm) into the plug hole to lock the counterbalance shaft.

Plug

Screwdriver 6EN1026


Aug. 1998

PWEE9616-A

Revised

11A-10-4



(3) Loosen the flange bolt.

6EN0565

AF" COUNTERBALANCE SHAFT FRONT BEARING REMOVAL (1) Using the special tool, remove the counterbalance shaft front bearing from the cylinder block. NOTE Be sure to remove the front bearing first. If it has not been removed, the Rear Bearing Puller cannot be used.

AG" COUNTERBALANCE SHAFT REAR BEARING REMOVAL (1) Using the special tool, remove the left counterbalance shaft rear bearing from the cylinder block.

MB991603

NOTE When removing the left counterbalance shaft rear bearing, install the special tool (MB991603) in front of the cylinder block.

INSTALLATION SERVICE POINTS "AA RIGHT COUNTERBALANCE SHAFT REAR BEARING INSTALLATION (1) Apply engine oil to the outer surface of bearing. (2) Using special tools, install right rear bearing. Make sure that oil hole of bearing is aligned with oil hole of cylinder block.

MD998705

6EN1034


Aug. 1998

PWEE9616-A

Revised


11A-10-5


"BA LEFT COUNTERBALANCE SHAFT REAR BEARING INSTALLATION (1) Install the special tool (Guide Plate) to the cylinder block. (2) Apply engine oil to the rear bearing outer circumference and bearing hole in the cylinder block.

MB991603

(3) Using the special tool, install the rear bearing. Rear bearing

MB991603

NOTE The left rear bearing has no oil holes.

MD998705 6EN0557

"CA COUNTERBALANCE SHAFT FRONT BEARING INSTALLATION (1) Using special tools, install front bearing.

MD998705

MD998705 Bearing

Cylinder block

6EN1035

"DA COUNTERBALANCE SHAFT OIL SEAL INSTALLATION


Aug. 1998

PWEE9616-A

Revised

11A-10-6



"EA OIL PUMP OIL SEAL INSTALLATION

"FA CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Using the special tool, install the crankshaft front oil seal into the front case.

"GA OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION (1) Apply engine oil amply to the gears and line up the alignment marks.

"HA FRONT CASE ASSEMBLY INSTALLATION (1) Set the special tool on the front end of crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.

(2) Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket).


Aug. 1998

PWEE9616-A

Revised


11A-10-7


"IA SEALANT APPLICATION TO OIL PRESSURE SWITCH (1) Coat the threads of switch with sealant and install the switch using the special tool. Specified sealant: 3M ATD Part No. 8660 or equivalent Caution D Keep the end of the thread portion clear or sealant. D Avoid an overtightening.

"JA FLANGE BOLT INSTALLATION (1) Insert a Phillips screwdriver into a hole in the left side of the cylinder block to lock the silent shaft.

6EN0564

(2) Secure the oil pump driven gear onto the left counterbalance shaft by tightening the flange bolt to specified torque.

MD998162

"KA PLUG INSTALLATION (1) Install a new O-ring to the groove of front case. (2) Using the special tool, install the plug and tighten to specified torque.

MD998783

"LA OIL PAN INSTALLATION (1) Clean both mating surfaces of oil pan and cylinder block. (2) Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan flange. Specified sealant: Mitsubishi Genuine equivalent Bolt hole portion E Mitsubishi Motors Corporation

Part

No.

MD970389

or

Groove portion 6EN0213 Aug. 1998

PWEE9616-A

Revised

11A-10-8



NOTE (1) Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx. one hour.

(3) Note the difference in bolt lengths at the location shown.

"MAOIL PAN UPPER / OIL PAN LOWER INSTALLATION (1) Clean both mating surfaces of oil pan and cylinder block. (2) Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan upper flange.

Oil pan upper

Specified sealant: Mitsubishi Genuine equivalent Groove portion

Bolt hole portion

Part

No.

MD970389

or

NOTE (1) Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealant area away from the oil and coolant for approx. one hour.

(3) Note the difference in bolt lengths at the location shown.

Timing belt side

M6 ´ 16 mm


Aug. 1998

PWEE9616-A

Revised


11A-10-9


(4) Clean both mating surfaces of oil pan lower and oil pan upper. (5) Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan lower flange.

Oil pan lower

Bolt hole portion

Groove portion

1 4

Part

No.

MD970389

or

NOTE (1) Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealant area away from the oil and coolant for approx. one hour.

(6) Tighten the oil pan lower mounting bolts in the sequence shown in the illustration.

8

6

Specified sealant: Mitsubishi Genuine equivalent

3 5

2

9

7

Oil pan side

"NA DRAIN PLUG GASKET INSTALLATION (1) Install the drain plug gasket in the shown direction.

Drain plug gasket

7EN0307

Bracket side

"OA OIL FILTER INSTALLATION (1) Clean the installation surface of the filter bracket. (2) Apply engine oil to the O-ring of the oil filter. (3) Screw the oil filter in until the O-ring contacts the bracket. Then tighten 3/4 turn (tightening torque: 16 Nm). NOTE For the oil filter MD135737, tighten one turn (Tightening torque: 14 Nm) after the O-ring contacts the bracket.

6EN0591


Aug. 1998

PWEE9616-A

Added

11A-10-10 4G6 ENGINE (E - W) -


INSPECTION FRONT CASE (1) Check oil holes for clogging and clean if necessary. (2) Check the left counterbalance shaft front bearing section for wear, damage and seizure. If there is anything wrong with the section, replace the front case. (3) Check the front case for cracks and other damage. Replace cracked or damaged front case.

OIL SEAL (1) Check the oil seal lip for wear and damage. Replace oil seal if necessary. (2) Check the oil seal lip for deterioration. Replace oil seal if necessary.

COUNTERBALANCE SHAFT (1) Check oil holes for clogging. (2) Check journals for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace the counterbalance shaft, bearing or front case assembly.

OIL PUMP (1) Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness. (2) Ensure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover. (3) Check the side clearance. Standard value: Drive gear Driven gear


Aug. 1998

PWEE9616-A

0.08 - 0.14 mm 0.06 - 0.12 mm

Added

4G6 ENGINE (E - W) - Piston and Connecting Rod

11. PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION


6 7 8

4 10

12

9 11

5

3 2 1

"GA AA" "FA "EA "DA "EA "CA

Removal steps 1. Nut 2. Connecting rod cap 3. Connecting rod bearing 4. Piston and connecting rod assembly 5. Connecting rod bearing 6. Piston ring No. 1


Dec. 1996

"CA 7. Piston ring No. 2 "BA 8. Oil ring AB" "AA 9. Piston pin 10. Piston 11. Connecting rod 12. Bolt PWEE9616

11A-11-1

11A-11-2

4G6 ENGINE (E - W) - Piston and Connecting Rod REMOVAL SERVICE POINTS AA" CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.

AB" PISTON PIN REMOVAL

(1) Insert the special tool, Push Rod, into the piston from the side on which the front mark is stamped in the piston head, and attach the guide C to the push rod end. (2) Place the piston and connecting rod assembly on the special tool, Piston Pin Setting Base, with the front mark facing upward. (3) Using a press, remove the piston pin. NOTE Keep the disassembled pistons, piston pins and connecting rods in order according to the cylinder number.


Dec. 1996

PWEE9616


11A-11-3

INSTALLATION SERVICE POINTS "AA PISTON PIN INSTALLATION (1) Measure the following dimensions of the piston, piston pin and connecting rod. A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod small end width (2) Obtain dimension L (to be used later) from the above measurements by using by following formula. L =

(A - C) - (B - D) 2

(3) Insert the special tool, Push Rod, into the piston pin and attach the guide A to the push rod end. (4) Assemble the connecting rod in the piston with their front marks facing the same direction. (5) Apply engine oil to the entire periphery of the piston pin. (6) Insert the piston pin, push rod and guide A assembly having assembled in step (3) from the guide A side into the piston pin hole on the front marked side. (7) Screw the guide B into the guide A until the gap between both guides amounts to the value L obtained in step (2) plus 3 mm.

3 mm + L

(8) Place the piston and connecting rod assembly onto the piston setting base with the front marks directed upward. (9) Press-fit the piston pin using a press. If the press-fitting force required is less than the standard value, replace the piston and piston pin set or/and the connecting rod. Standard value: 7,350 - 17,200 N


Dec. 1996

PWEE9616

11A-11-4

4G6 ENGINE (E - W) - Piston and Connecting Rod (10)Check that the piston moves smoothly

Upper side rail

Spacer

Lower side rail 6EN1237

"BA OIL RING INSTALLATION (1) Fit the oil ring spacer into the piston ring groove. NOTE 1. The side rails and spacer may be installed in either direction. 2. New spacers and side rails are colored for identification of their sizes. Size

Identification color

Standard

None

0.50 mm oversize

Red

1.00 mm oversize

Yellow

(2) Install the upper side rail. To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into position by finger. See illustration. Use of ring expander to expand the side rail end gap can break the side rail, unlike other piston rings.

Side rail gap

Caution D Do not use piston ring expander when installing side rail. 1EN0269


Dec. 1996

(3) Install the lower side rail in the same procedure as described in step (2). (4) Make sure that the side rails move smoothly in either direction.

PWEE9616

11A-11-5


"CA PISTON RING NO. 2 / PISTON RING NO. 1 INSTALLATION (1) Using piston ring expander, fit No. 2 and then No. 1 piston ring into position. NOTE 1. The ring end is provided with identification mark. Item No. 1 ring No. 2 ring

Identification mark Identification mark

Side mark

No. 1 No. 2

9EN0524

Identification mark 4G63 SOHC

1R

4G64 GDI

T

4G63 SOHC

2R

4G64 GDI

2T

2. Install piston rings with identification mark facing up, to the piston crown side. 3. Size marks on position rings are as follows. Size

Size mark

Standard

None

0.50 mm oversize

50

1.00 mm oversize

100

"DA PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION (1) Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the figure. (3) Rotate the crankshaft so that crank pin is on the center of cylinder bore.

Timing belt side

(4) Use suitable thread protectors on the connecting rod bolts before inserting piston and connecting rod assembly into the cylinder block. Care must be taken not to nick the crank pin. (5) Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.

"EA CONNECTING ROD BEARINGS INSTALLATION When the bearing needs replacing, select and install a proper bearing by the following procedure. (1) Measure the crankshaft pin diameter and confirm its classification from the following table. In the case of a crankshaft supplied as a service part, identification colors of its pins are painted at the positions shown in the illustration.


Aug. 1998

PWEE9616-A

Revised

11A-11-6

4G6 ENGINE (E - W) - Piston and Connecting Rod (2) The connecting rod bearing identification mark is stamped at the position shown in the illustration. Crankshaft pin Classification

Identification mark

Connecting rod bearing

Identification mark


O. D. mm

Identification mark

Thickness mm

Production part

Service part

1

None

Yellow

44.995 - 45.000

1

1.478 - 1.491

2 3

None

None

44.985 - 44.995

2

1.491 - 1.495

None

White

44.980 - 44.985

3

1.495 - 1.499

Connecting rod I.D.: 48.000 - 48.015 mm (3) Select a proper bearing from the above table on the basic of the identification data confirmed under items (1) and (2). [Example] If the measured value of a crankshaft pin outer diameter is 44.996 mm, the pin is classified as “1” in the table. In case the crankshaft is also replaced by a spare part, check the identification colors of the pins painted on the new crankshaft. If the color is yellow, for example, the pin is classified as “1”. In the above cases, select the connection rod bearing having identification mark “1”.

"FA CONNECTING ROD CAP NUT INSTALLATION (1) Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with no index mark, make sure that the bearing locking notches come on the same side as shown.

(2) Make sure that the connecting rod big end side clearance meets the specification. Standard value: 0.10 - 0.25 mm Limit: 0.4 mm


Dec. 1996

PWEE9616


11A-11-7

"GA CONNECTING ROD CAP NUT INSTALLATION Caution D If the cylinder head has been installed before installing the connecting rod cap nut, be sure to remove the spark plugs.

Paint mark

Paint mark

90_ - 100_

Nut

Bolt 6AE0298

(1) Since the connecting rod cap bolts and nuts are torqued using the plastic area tightening method, the bolts should be examined BEFORE reuse. If the bolt threads are “necked down”, the bolt should be replaced. Necking can be checked by running a nut with fingers to the full length of the bolt threads. If the nut does not run down smoothly, the bolt should be replaced. (2) Before installation of each nut, apply engine oil to the thread portion and bearing surface of the nut. (3) Install each nut to the bolt and tighten it with fingers. Then tighten the nuts alternately to install the cap properly. (4) Tighten the nuts to a torque of 20 Nm. (5) Make a paint mark on the head of each nut. (6) Make a paint mark on the bolt end at the position 90_ to 100_ from the paint mark made on the nut in the direction of tightening the nut. (7) Give a 90_ to 100_ turn to the nut and make sure that the paint mark on the nut and that on the bolt are in alignment. Caution D If the nut is turned less than 90_, proper fastening performance may not be expected. When tightening the nut, therefore, be careful to give a sufficient turn to it. D If the nut is overtightened (exceeding 100_), loosen the nut completely and then retighten it by repeating the tightening procedure from step (1).

INSPECTION PISTON RING (1) Check the piston ring for damage, excessive wear, and breakage and replace if defects are evident. If the piston has been replaced with a new one, the piston rings must also be replaced with new ones. (2) Check for the clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both. Standard value: 0.02 - 0.06 mm Limit: 0.1 mm


Dec. 1996

PWEE9616

11A-11-8

4G6 ENGINE (E - W) - Piston and Connecting Rod (3) Install the piston ring into the cylinder bore. Force it down with a piston, its crown being in contact with the ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge. If the ring gap is excessive, replace the piston ring. Standard value: No. 1 ring 0.25 - 0.35 mm No. 2 ring 0.40 - 0.55 mm Oil ring 0.10 - 0.40 mm Limit: No. 1, No. 2 ring 0.8 mm Oil ring 1.0 mm

CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft pin and connecting rod bearing. (2) Cut the Plastigage to the same length as the width of the bearing and place it on the crankshaft pin in parallel with its axis. Plastigage

(3) Install the connecting rod cap carefully and tighten the nuts to specified torque. (4) Carefully remove the connecting rod cap. (5) Measure the width of the Plastigage at its widest part by using a scale printed on the Plastigage package. Standard value: 0.02 - 0.05 mm Limit: 0.1 mm


Dec. 1996

PWEE9616

11A-12-1

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate

12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 3 2


11 Nm

1

10 132 Nm

13

4

12

21

A

5

11

11 Nm

9 Nm

7 8

132 Nm

6

9 19

20

18

17

8

132 Nm

7 6

9

16 15

14

"FA "EA "DA "DA "CA

Removal steps 1. Flywheel bolt 2. Adapter plate 3. Flexible flywheel 4. Adapter plate 5. Crankshaft bushing 6. Drive plate bolt 7. Adapter plate 8. Drive plate 9. Crankshaft bushing 10. Rear plate 11. Bell housing cover 12. Oil seal case 13. Oil seal 14. Bearing cap bolt 15. Bearing cap 16. Crankshaft bearing, lower


Aug. 1998

17. Crankshaft "CA 18. Crankshaft bearing, upper "BA 19. Crankshaft thrust bearing AA" "AA 20. Oil jet 21. Cylinder block Caution On the flexible wheel equipped engines, do not remove any of the bolts “A” of the flywheel shown in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt, therefore, can cause the flexible flywheel to be out of balance, giving damage to the flywheel. PWEE9616-A

Revised

11A-12-2

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate REMOVAL SERVICE POINT AA" OIL JET REMOVAL (1) Knock out the oil jets using an appropriate metal rod. Caution D Be careful not to scratch the cylinder wall. D Do not reuse the removed oil jets.

INSTALLATION SERVICE POINTS "AA OIL JET INSTALLATION (1) Using a 4.5 mm diameter pin punch, drive in the oil jet to the crankshaft journal until it seats to the bottom.

"BA CRANKSHAFT THRUST BEARING INSTALLATION (1) Install the two thrust bearing in the number 3 bearing bore in the cylinder block. For easier installation, apply engine oil to the bearings; this will help hold them in position. (2) The thrust bearings must be installed with their groove side toward the crankshaft web. Groove

Identification color of crankshaft journal


Aug. 1998

"CA CRANKSHAFT BEARING INSTALLATION (1) From the following table, select a bearing whose size is appropriate for the crankshaft journal outside diameter.

PWEE9616-A

Revised


11A-12-3

Bearing bore size identification mark No. 1

No. 2 No. 3

No. 4

No. 5 Bearing bore identification mark

Cylinder inner diameter size mark

Rear face of cylinder block

Bottom of cylinder block

Crankshaft journal outside diameter

Cylinder block bearing bore

Crankshaft bearing

Crankshaft for No. 3


Size mm

Identification mark

Identification mark or color

Identification mark or color

Yellow

56.994 - 57.000

0

1 or Green

0 or Black

1

2 or Yellow

1 or Green

2

1 or Green

2 or Yellow

0

2 or Yellow

1 or Green

1

3 or None

2 or Yellow

2

2 or Yellow

3 or None

0

3 or None

2 or Yellow

1

4 or Blue

3 or None

2

5 or Red

4 or Blue

None

White

56.988 - 56.994

56.982 - 56.988

Crankshaft bearing size identification mark or color

Identification mark or color E Mitsubishi Motors Corporation

Aug. 1998

bearing

For example, if the crankshaft journal outside diameter ID color is “yellow” and cylinder block bearing bore ID mark is “1”, select a bearing whose ID mark is “2” or ID color is “yellow” for number 1, 2, 4 and 5, and a bearing whose ID mark is “1” or ID color is “green” for number 3. If there is no ID color paint on the crankshaft, measure the journal outside diameter and select a bearing appropriate for the measured value.

PWEE9616-A

Revised

11A-12-4

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate (2) Install the bearings having an oil groove to the cylinder block. (3) Install the bearings having no oil groove to the bearing cap.

Groove

Upper Lower

"DA BEARING CAP / BEARING CAP BOLT INSTALLATION (1) Install the bearing caps so the arrow points to the timing belt side. (2) Before installing the bearing cap bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolt. Shank length

Limit: Max. 71.1 mm 9EN0477

(3) Apply engine oil to the threaded portion and bearing surface of the bolt. (4) Tighten the bolts to 25 Nm in the specified tightening sequence.

Arrow mark

Paint mark

Paint mark

90_ - 100_

6AE0299


Aug. 1998

(5) Make a paint mark on the head of each bolt. (6) Make a paint mark on the bearing cap at the position 90_ to 100_ from the paint mark made on the bolt in the direction of tightening the bolt. (7) According to the specified tightening sequence, give a 90_ to 100_ turn to each bolt and make sure that the paint mark on the bolt and that on the cap are in alignment. Caution D If the bolt is turned less than 90_, proper fastening performance may not be expected. When tightening the bolt, therefore, be careful to give a sufficient turn to it. D If the bolt is overtightened (exceeding 100_), loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1).

PWEE9616-A

Revised


11A-12-5

(8) After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace No. 3 crankshaft bearings. Standard value: 0.05 - 0.18 mm Limit: 0.25 mm

"EA OIL SEAL INSTALLATION

"FA SEALANT APPLICATION TO OIL SEAL CASE Specified sealant: Mitsubishi Genuine equivalent

Part

No.

MD970389

or

NOTE (1) Be sure to install the case quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx. one hour.

INSPECTION

Plastigage

CRANKSHAFT OIL CLEARANCE (PLASTIGAGE METHOD) (1) Remove oil from the crankshaft journal and the crankshaft bearing. (2) Install the crankshaft. (3) Cut the Plastigage to the same length as the width of the bearing and place it on the journal in parallel with its axis. (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque. (5) Carefully remove the crankshaft bearing cap. (6) Measure the width of the Plastigage at its widest part by using a scale printed on the Plastigage package. Standard value: 0.02 - 0.04 mm Limit: 0.1 mm Plastigage E Mitsubishi Motors Corporation

Aug. 1998

PWEE9616-A

Revised

11A-12-6

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate CYLINDER BLOCK (1) Visually check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct, or replace. (2) Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter. Standard value: 0.05 mm Limit: 0.1 mm (3) If the distortion is excessive, correct within the allowable limit or replace. Grinding limit: 0.2 mm Includes/combined with cylinder head grinding Cylinder block height (when new): 4G63 284 mm 4G64 290 mm (4) Check cylinder walls for scratches and seizure. If defects are evident, correct (bored to oversize) or replace.

(5) Using cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, correct cylinder to an oversize and replace piston and piston rings. Measure at the points shown in illustration. Standard value: Cylinder I.D. 4G63 85.00 - 85.03 mm 4G64 86.50 - 86.53 mm Cylindricity 0.01 mm or less

BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification Size

Identification mark

0.50 O.S.

0.50

1.00 O.S.

1.00

NOTE Size mark is stamped on the piston top. (2) Measure outside diameter of piston to be used. Measure it in thrust direction as shown. (3) Based on the measured piston O.D. calculate boring finish dimension. Boring finish dimension = Piston O.D. + (clearance between piston O.D. and cylinder) - 0.02 mm (honing margin)


Aug. 1998

PWEE9616-A

Revised


11A-12-7

(4) Bore all cylinders to the calculated boring finish dimension. Caution D To prevent distortion that may result from temperature rise during honing, bore cylinders, working from No. 2, No. 4, No. 1 to No. 3. (5) Hone to final finish dimension (piston O.D. + clearance between piston O.D. and cylinder). (6) Check clearance between piston and cylinder. Clearance between piston and cylinder: 0.02 - 0.04 mm NOTE When boring cylinders, finish all of four cylinders to same oversize. Do not bore only one cylinder to an oversize.


Aug. 1998

PWEE9616-A

Added

NOTES

Mitsubishi Engine 4G6

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